Looking for help / High pressure fuel pump 1.6 FSI

VVVVVV

Member
Finland
Hello! I'm a fairly new A2 1.6 FSI 2004 owner. But now a really annoying bug appeared on my wonderful car.

My problem is that the car starts poorly or not at all if the engine is warm (about 90° or less). But if you can get the car to start, it works like normal.

I have taken the car in for maintenance. Now the spark plugs and coils have been changed. Also Fuel pressure sensor (Bosch) and most recently all four injection valves (Bosch). Only poor running / misfire is now gone... but the startup problems just continue the same way, argh! The car's timing belt has been replaced in 2019 (79,000 kilometers on the odometer), so belt stretching/wear should not be a problem. Also the repairman said that it is ok. Today there is about 86,000 kilometers on the odometer. That is, quite a bit for her age.

Next thing is the High Pressure Fuel pump on the line...
Does anyone have a tips where to get a replacement pump?

I wouldn't want to leave the A2 on the side of the road :(

Br. A slightly desperate A2 owner.
 
Why don't you upgrade your account to get Market access (details will be in the Welcome email you received) and you can put up a Wanted advert for a HPFP if you can't find one listed for sale there.
 
Good Evening,

86,000 kilometres is quite low, not much at all really! As you have chosen to use kilometres I assume it is kilometres and not miles but it is difficult to tell from your obtuse location, but even if it was miles it is not high at all.

You have spent quite a lot money already on parts just 4 new injectors + labour costs is enough and now you want an expensive high pressure fuel pump, why? What suggests this is needed? They are quite rare and at least one member repaired their HPP.

Have you any diagnostic reports you could post, preferably VCDS?

Andy
 
Hello! I'm a fairly new A2 1.6 FSI 2004 owner. But now a really annoying bug appeared on my wonderful car.

My problem is that the car starts poorly or not at all if the engine is warm (about 90° or less). But if you can get the car to start, it works like normal.

I have taken the car in for maintenance. Now the spark plugs and coils have been changed. Also Fuel pressure sensor (Bosch) and most recently all four injection valves (Bosch). Only poor running / misfire is now gone... but the startup problems just continue the same way, argh! The car's timing belt has been replaced in 2019 (79,000 kilometers on the odometer), so belt stretching/wear should not be a problem. Also the repairman said that it is ok. Today there is about 86,000 kilometers on the odometer. That is, quite a bit for her age.

Next thing is the High Pressure Fuel pump on the line...
Does anyone have a tips where to get a replacement pump?

I wouldn't want to leave the A2 on the side of the road :(

Br. A slightly desperate A2 owner.
As @Andrew has said, get it scanned with a vag specific scan tool. Then post the report on here for guidance.
You or your mechanic, are, quite probably, wasting time and money, (and getting frustrated), changing parts based on educated guesses.
Check the free scan register to find a local member who can scan it for you. https://www.a2oc.net/community/index.php?threads/free-scan-register.44124/
Welcome to the fold, and good luck.
Mac.
 
Thanks so much for your help everyone!

I'm attaching some pictures, which mainly show misfires and fault finding with the help of a mechanic. I would be happy if the fault could be found somewhere else, but I'm about to run out of ways... and forces.

Referring to the attached pictures (sorry for the direct translation):

"Based on these, the nozzles were changed, the running waved and with partial throttle the 2nd cyl nozzle stuck like hell. Now there are no more misfires after changing the nozzles. But starting the car is difficult, especially when the engine is warm, but when it starts, it works normally.

Transfer pressure measured from the tank pump and it is approx. 4 bar, ok. For some reason, I can't see the pressure value produced by the high-pressure pump with my own testers, but today I'm still trying to connect it to the vac com to the tester of another repair shop.

But I strongly suspect that the high-pressure pump cannot produce enough pressure when starting, especially when warm. But when you start it with the starter pilot and the machine spins faster, it immediately starts and stays running."

I'll list something else that could cause the error:
• Belt, bottom pulley missing teeth
• Manifold flaps
• ECU (remap)
• Only high octane petrol should be used

Kilometers and not miles because the car is in Finland 🇫🇮

Br. A slightly desperate A2 owner.
 

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Hello! I'm a fairly new A2 1.6 FSI 2004 owner. But now a really annoying bug appeared on my wonderful car.

My problem is that the car starts poorly or not at all if the engine is warm (about 90° or less). But if you can get the car to start, it works like normal.

I have taken the car in for maintenance. Now the spark plugs and coils have been changed. Also Fuel pressure sensor (Bosch) and most recently all four injection valves (Bosch). Only poor running / misfire is now gone... but the startup problems just continue the same way, argh! The car's timing belt has been replaced in 2019 (79,000 kilometers on the odometer), so belt stretching/wear should not be a problem. Also the repairman said that it is ok. Today there is about 86,000 kilometers on the odometer. That is, quite a bit for her age.

Next thing is the High Pressure Fuel pump on the line...
Does anyone have a tips where to get a replacement pump?

I wouldn't want to leave the A2 on the side of the road :(

Br. A slightly desperate A2 owner.
Hi VVVVVV,
Worth checking fuel cap is the correct one for the FSI engine I believe (cheap /no cost )
 
VCDS will give you an positive answer about the high pressure pump, and many other things. Non VAG specific scan tools may not give accurate readings, particularly when used on the FSI engine, which has data blocks and error codes unique to it.
You should get access to the correct diagnostic tools before replacing more parts. This is not just a waste of money, but may introduce new faults that will make things worse.
Mac.
 
Thanks @PlasticMac We are trying to get the car into the VAC scan tool. Or to the Audi center.

Fingers crossed.
Not sure if where you are is similar to UK, where we would look for independent VAG specialists. Audi dealers are often only knowledgeable about modern models, and have little interest in older cars.
Please post the initial scan report on here, and we will give you all the help we can to get your FSI back good health.
Are there many A2s in France.
The MK4 Golf, and Lupo also had the FSI engine, so maybe look for VW specialists, as well as Audi. 🤞
Mac.
 
Not sure if where you are is similar to UK, where we would look for independent VAG specialists. Audi dealers are often only knowledgeable about modern models, and have little interest in older cars.
Please post the initial scan report on here, and we will give you all the help we can to get your FSI back good health.
Are there many A2s in France.
The MK4 Golf, and Lupo also had the FSI engine, so maybe look for VW specialists, as well as Audi. 🤞
Mac.
In VCDS, Group 140 will help with fuel pressures.
Block 140.2 Is the required, (by the ECU), fuel pressure, in Bar, at the injector rail
Block 140.3 Is the actual measured fuel pressure in Bar, at the injector rail
Mac.
 
Cheers👍
I have done 15k miles in the last year in the fsi, now sitting at 118k so I guess it is entering into its twilight period. Must say, it has been running pretty well but needs a couple of faults removing with the obd every 250ish miles. Fuel is around 45mpg however, that is good when you consider the speed it is kept at🤭
The 1.4 will be brought online in May and since I need to remove a vehicle it may have to go….. unless I make room in the garage then it can sit in there. Many parts then can be available for the 1.4 (body parts etc).
 
This is starting to be a Sherlock Holmes-level stuff 🕵️‍♂️

"Went to check with another tester yesterday and the high fuel pressure does not rise when the car's starter motor spins the engine, but when the engine is made to spin harder, the pressure rises to approx. 60 bar and the car starts."

The repairman said the pump is broken/loose... I don't have any pictures of this test yet. I think it was VAG com.
 
This is starting to be a Sherlock Holmes-level stuff 🕵️‍♂️

"Went to check with another tester yesterday and the high fuel pressure does not rise when the car's starter motor spins the engine, but when the engine is made to spin harder, the pressure rises to approx. 60 bar and the car starts."

The repairman said the pump is broken/loose... I don't have any pictures of this test yet. I think it was VAG com.
Just a gut reaction to what you describe, I'm thinking fuel pressure relief valve.
Might think differently in the morning, but if the pump generates 60Bar, with engine running, it's not number one suspect.
Mac.
 
This is starting to be a Sherlock Holmes-level stuff 🕵️‍♂️

"Went to check with another tester yesterday and the high fuel pressure does not rise when the car's starter motor spins the engine, but when the engine is made to spin harder, the pressure rises to approx. 60 bar and the car starts."

The repairman said the pump is broken/loose... I don't have any pictures of this test yet. I think it was VAG com.
Good Evening,

60 bar is normal. Was the engine warm (up to running temperature)? Pity they did not log group 140 (with group 001) with VCDS while trying to start so there would be evidence. Any faults showing on VCDS?

As high pressure pumps are quite expensive I would consider repair. Only(!!!!!) £2000 new but a used one available on ebay


Andy
 
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Just a gut reaction to what you describe, I'm thinking fuel pressure relief valve.
Might think differently in the morning, but if the pump generates 60Bar, with engine running, it's not number one suspect.
Mac.
Thanks, I could discuss these parts with a mechanic. At some point I have to start bribing him to help me with this project 🫡

Fuel pressure regulator
BOSCH DR230BAR, BOSCH DR230bar
Item number: 0 280 160 557
(suitable A2 (8Z0) 110 HP / 81 KW 200205 - 200508)

+ Maybe... Breather Valve, fuel tank
BOSCH 0 280 142 347
Item number: 0 280 142 347
(suitable A2 (8Z0) 110 HP / 81 KW 200205 - 200508)
 
Good Evening,

60 bar is normal. Was the engine warm (up to running temperature)? Pity they did not log group 140 (with group 001) with VCDS while trying to start so there would be evidence. Any faults showing on VCDS?

As high pressure pumps are quite expensive I would consider repair. Only(!!!!!) £2000 new but a used one available on ebay


Andy
Thank you very much, I already asked more about the part. This is a really good tip (ebay .ie).

Maybe I explained that a little strangely in the previous message. I will try again...
"High pressure does not rise when the car's starter motor turns the engine. But with assisted start (assisted to spin harder) the pressure rises to 60 bar and the car starts. The conclusion from this is that the pump is broken/leaking." But the starter motor and battery are fine.

I'm pretty sure the car was measured when engine is warm. I think that this fault only appears when the machine is warm. I'll ask for more info (about the tester and the situation) when I'm back in town.
 
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