A6 2.5 TDi injection pump - fault codes / immobiliser

[ss43]

I am working on a 2003 A6 2.5 TDi, engine code BFC
It repeatedly brings up the following fault codes on my VCDS and frequently goes into limp mode:
Address 01: Engine Labels: 059-907-401-AKE.clb

00550 - Start of Injection Regulation
08-10 - Control Limit Surpassed - Intermittent
00550 - Start of Injection Regulation
17-10 - Control Difference - Intermittent
Readiness: N/A
-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 4B0-614-517.lbl
Part No: 4B0 614 517 G
Component: ABS/ESP front 1728

1 Fault Found:
18265 - Load Signal
P1857 - 35-10 - Error Message from ECU - Intermittent

As of last night, the car is now also smoking badly, knocking and barely running.

I think this could be either the injection pump (mechanical issue), or the injector needle lift sensor, or Air Massflow Meter.
I have two questions:
1. Are there any more checks that I can do to eliminate or confirm any of the above before I start spending money on replacement parts?
2. If I remove (unplug) and then refit the same injection pump will, do I need the Immobiliser SKC/PIN in order to prevent the vehicle immobilising? It is Immo 3. (I know I need the SKC to fit a different pump, but what about simply removing and refitting the same pump)

Needless to say, I do not have the SKC, my dealer won't provide it and I don't have enough talent to extract it from the Magneti Marelli cluster, so any help with that would also be very welcome.

Any comments welcome.

[ceilidhalfie]

00550 - Start of Injection Regulation: Control DifferencePossible Symptoms

Malfunction Indicator Light (MIL) ON
Loss of Power
Starting Problems
Transmission in Emergency Mode

Possible Causes

Fuel Tank incorrectly filled with Petrol or Biodiesel
Air/Water in Fuel System
Injection Timing incorrect
Electrical Fuel Pump faulty

Possible Solutions

Check Fuel Tank for Petrol and Biodiesel

Drain Tank and Fuel System


Check Fuel System for Air/Water
Check Fuel Supply and Return Lines for Blockage and Leaks
Check Electrical Fuel Pump
Check/Correct Injection Timing

Perform Basic Setting / Use TDI-Graph



Have you changed the fuel filter recently? Have you altered fuel injection pump timing? Unlikely a problem with needle lift sensor. If sensor faulty Engine Management uses default settings. What "work" were you doing?

[ametlib]

Hi,
your dealer cant give you the code even if he want to, good thing is you don't need it to take the IP off/on.
The fault code from ABS controller is simply that it have recieved a code from the Engine Controller (ECU) The ECU code is about timing and there are at least 3 possible explainations for the problem.
1- Something about the pump belt/ tentioner, unlikely though. 2- your pump is not getting fuel- clogged up pickup in tank or water/debris in fuel filter. 3- you're out of luck and need a new Injection pump, stuck advance piston, EDC ontop braindead, cracked diaphragm or
something else funny.
Have you checked the timing in basic settings 4 ?

[ss43]

Thanks Ametlib and Ceilidhalfe for your comments. The situation has developed further over the past couple of days. The question of 'What "work" were you doing?' was a very relevant question.

The auxiliary (poly-vee) belt tensioner failed a few months ago and I replaced two poly-vee belts on the front of the engine, some pulleys and the tensioner unit with the damper in it. I also carefully removed any debris from the shredded belts that I could see. I had replaced the toothed belts about a year earlier and they seemed OK so I left them as they were.

Sometime after that the car produced some fault codes, but it still ran reasonably well some of the time (a little rough) and went into limp mode at other times. I thought it might be the Airflow Meter. However, it got much worse on Monday and I pulled it apart. Sadly I found another piece of debris from the shredded poly-vee belt. It seems this had found its way around the cambelt belt and the cambelt had slipped about 20 degrees on the crankshaft pulley. Pretty disastrous! The car was still running - just about - but there was some mechanical noise and I feel there must have been valve/piston contact.

I have rocker covers removed and there is plenty of camshaft wear, so those need replaced anyway (182k miles). I am removing the cylinder heads later to assess the valve situation, and I'll post a further update.

I don't know how I missed the offending piece of belt debris because I checked really carefully. I suspect it may have got wedged between the inner and outer section of the damped pulley assembly on the front of the crankshaft and then worked its way out again some time later. Anyway, the injection pump error messages probably derive from the timing having moved.

Does anyone know a good value source for KS or other good quality camshafts and followers?

Has anyone got a decent AKE engine for sale? (If I'm doing all this work, I'd like to upgrade to the AKE spec to get a bit more power). I think the only difference between the AKE and my BFC is the injector pump, the fuel cooling heat exchanger and the ECU.

I now understand why someone in another thread referred to the poly-vee belt tensioner as the 'grenade'. A very accurate description.

[ametlib]

Ake ? I can see some immo problems in the horizont ...At least don't mess up and bring in ist gen. AKE pump ( E ) as it have no immo in the pump EDC. I doubt that the cluster in yours will accept an ECU for a pump without immo. Much, much easier and cheaper to chip the one you have .