Injection Pump / Sensor fault

[S4_dan]

Hi,

Put my car on VAG-COM and got the same code!

00542 - Needle lift sensor (G80)
30.10 - Open or short to B+

this is on a 2.5 V6 TDi, 2001.

spoke with Audi and a mate at VW.

Audi wouldn't give me any information about the part or fault unless i paid them to put my car on their diagnostics system to give them te same error code i did!! Alan (customer services guy, nice chap) told me the name of a company who can refurb the unit and that its not that of a UNcommon fault!

However, VW, my mate called an engineer over who told me that the needle lift sensor is (on most diesel engines) inside the INJECTOR PUMP unit..costing £1436.00 + VAT on an exchange basis! /ubbthreads/images/graemlins/frown.gif

Good job i was already sat down!!!

Could be lucky, the sensor mght not be in the unit (but knowing my luck...it WILL be!) Only way I will defo know is to give car to Audi and let them check it!

Details of the company that Audi told me about can be found HERE!

I've emailed them and as soon as I get a response I will post back.

has anyone ever cleaned/opened and injection pump???

 

[fjtwelve]

And i just bought one of these cars (well the 180hp) with 110000 on it. Better enjoy the next few miles while i can afford it. Please keep us updated.

 

[Jason]

What are your symptoms that prompted you to connect up to vag.com that makes you think that you have a problem with your injection pump?

And just because it gives you a fault code you are thinking about taking your injection pump in bits! Which I would seriously recommend you not to do! Proper specialist job!
I once changed some external leaking o-rings on a Audi 100 .Audi don't do bits for pumps just exchange them, so got the bits from a diesel specialist!

All cars are now over flowing with dodgy electronics, the wife's New beetle has the same problem as the A6 with the air bag,ESP, warning lights, etc... and the neighbours have the same problem with there Renaults,Peugeots & what ever, so I don't think that I would be trusting vag.com readings a 100% either!!!!!

Personaly I have never heard of any body changing a knacked injection pump on a VW/Audi

 

[S4_dan]

Symptons? None really that i'm aware off.

i have never driven another Audi 2.5 V6 A6 so i wouldnt know what to expect with performance and feel.

I was using the vag com to see if the ECU had recorded any faults from the maf sensor.

Have contacted a diesel pump specialist company and waiting for their return email.

 

[S4_dan]

Right, got my copy of Vag-com activated today.

I ran an Auto check on my car....here is the results!!! /ubbthreads/images/graemlins/cry.gif

VAG-COM Version: Release 311.2-N


Chassis Type: 4B - Audi A6 C5
Scan: 01,02,03,08,15,16,17,35,36,37,45,55,56

Address 01 -------------------------------------------------------
Controller: 4B0 907 401 AE
Component: 2.5l/4VTEDC G400SG D70
Coding: 01012
Shop #: WSC 02325
WAUZZZ4BZ1N0xxxxxx AUZ7xxxxxxxxxxxx
3 Faults Found:
00542 - Needle lift Sensor (G80)
30-00 - Open or Short to B+
00523 - Intake Air Temp Sensor (G42)
30-10 - Open or Short to B+ - Intermittent
00553 - Mass Air Flow Sensor (G70)
31-10 - Open or Short to Ground - Intermittent
Readiness: N/A

Address 03 -------------------------------------------------------
Controller: 3B0 614 111
Component: ABS/ASR 5.3 FRONT D00
Coding: 00012
Shop #: WSC 02325
No fault code found.

Address 08 -------------------------------------------------------
Controller:
Note: Excessive Comm Errors

Skipping Address 15-Airbags

Address 16 -------------------------------------------------------
Controller: 4B0 907 487 E
Component: Lenkradelektronik D04
No fault code found.

Address 17 -------------------------------------------------------
Controller: 4B0 920 981 B
Component: C5-KOMBIINSTR. VDO D12
Coding: 00460
Shop #: WSC 00001
WAUZZZ4BZ1xxxxxxxxx AUZ7Zxxxxxxxx
No fault code found.

Address 35 -------------------------------------------------------
Controller: 4B0 962 258 H
Component: Central Lock/Alarm D33
Coding: 06862
Shop #: WSC 02325
6 Faults Found:
01366 - Opened Due to Crash Signal
35-00 - -
01371 - Alarm triggered by Door Contact Switch: Driver's Side
35-00 - -
01572 - Alarm triggered by Door Contact Switch: Passenger Side
35-00 - -
01374 - Alarm triggered by Terminal 15
35-00 - -
01370 - Alarm triggered by Interior Monitoring
35-00 - -
01368 - Alarm triggered by Luggage Compartment Switch
35-00 - -

Address 45 -------------------------------------------------------
Controller: 4B0 951 173
Component: Innenraumueberw. D03
Coding: 00001
Shop #: WSC 02325
1 Fault Found:
01377 - Ultra Sonic Sensor for Alarm System: Left (G170)
27-10 - Implausible Signal - Intermittent

Address 56 -------------------------------------------------------
Controller: 4B0 035 186
Component: Radio 0001
No Faults Found
or DTCs not supported by controller
or a communication error ocurred

End -------------------------------------------------------


If i clear the codes, will the codes be displayed again upon next vagcom check if i dont repair/replace the faulty items?

I heard somewhere that if i cleared the codes, they wouldnt come back again? (please tell this is WRONG!)

Also, does anyone know where i can locate the Air intake Sensor? is it actually part of the MAF?

cheers

 

[dan1]

I had the G80 needle lift sensor issue on my car too, 2.5 v6 tdi 2002, replaced it for 200 squid and then rechecked Vag-com and the fault had gone.

Fairly easy job to do if your handy with engines, hardest part is to try and prime the diesel lines again for a quick and easy start.

car ran smoother after i had done the job. I had to find my part number to match up with the new one, was told not servicable by a number of different injector suppliers

 

[dan1]

sorry, forgot to mention.... will put all info as relevant as when I had the problem, no one seemed to know on this site what the issue was with the G80 sensor....

It is the middle injector on the left bank looking in at the engine from the front, it has a wire coming out of it which then goes to a socket in the bulkhead.

You need to remove the three injection lines on that side of the engine and then remove the rocker cover.

The injector can then be unbolted and removed, When refitting remember to put in a new copper washer at the bottom, torque up the bolts to 10 nm.

The G80 is not on the diesel pump.

Biggest issue I had was bleeding air outof the system.... damn pain in the a$se

Hope that helps

 

[S4_dan]

[ QUOTE ]
I had the G80 needle lift sensor issue on my car too, 2.5 v6 tdi 2002, replaced it for 200 squid and then rechecked Vag-com and the fault had gone.

Fairly easy job to do if your handy with engines, hardest part is to try and prime the diesel lines again for a quick and easy start.

car ran smoother after i had done the job. I had to find my part number to match up with the new one, was told not servicable by a number of different injector suppliers

[/ QUOTE ]

Thank you for the reply, where did you purchase your lift sensor from?

I reset my ecu and the fault has not come back.....my cambelt snapped a while back and it may of caused the fault to show up from then? Audi told me its in the pump?? mine is 2001 model AKN engine.

cheers Dan

 

[dan1]

wow, your cam belt snapped???? you were lucky to get through with just the belt change...

ok, here are the instructions for you:
-----------------------------------------

Servicing diesel direct injection system
Removing and installing injector with needle lift sender -G80
Removing injector with needle lift sensor

‒ Remove the right cylinder head cover.



‒ Remove the needle lift sensor -G80 connector (brown connector on front).
‒ → Undo the two nuts on the injector retainer (cylinder 3).
‒ Extract the injector and the needle lift sensor -G80.
If a cam prevents the injector from being extracted in a vehicle with a manual gearbox:

‒ Select 4th gear and push the vehicle forwards a little.
If a cam prevents the injector from being extracted in a vehicle with an automatic gearbox,

‒ Screw the retainer back onto the injector.
‒ Unplug connector from injection pump.
Important
Only operate the starter if all injectors are secured by retainers and the injection pump connector has been removed.
‒ Operate starter briefly.
‒ Remove the copper gasket (seal between injector and cylinder head) from the cylinder head.
Note:

The copper gasket must always be replaced.



Installing the injector and needle lift sensor

‒ → Insert the new injector, bush (2) and new copper gasket (1).
‒ When installing the injector, please ensure that the provided fitted pin (3) slides into the groove on the cylinder head.




‒ → Slide the injector cable through the retainer.
‒ Screw down the retainer with a torque of 10 Nm.
‒ → Lay the cable in the provided guide groove on the camshaft bearing -arrow-.
‒ Install the rubber cable seal (crescent) in the provided profile on the top of the cylinder head.
Note:

Do not slide the rubber seal (crescent) onto the cable (normally stuck on to provide a good seal).

‒ Re-install the right cylinder head cover.
--------------------------------------

Mine was fairly easy to do once the bitch of a cam cover cam off, all those metal diesel pipes in the way... my engine is AYM, so not sure what differences....

got mine from Vag-com, you may have to give them a part number from your old one as there are variations....

if you say that the error has gone away, for the sake of 200 pounds, i would wait until it came back and check once a week to see if it does... it might have been a fault that was thrown up with the belt issue and it has now gone.... the fault you threw up definetly is on the g80 needle flow, which is on an injector.... if you look in your engine at the injectors, can you see a lead that comes out of a cam cover? towards the middle of the engine? dont get it confused with the glow plug leads... if you do find it then that is the needle lift sensor lead... follow it and check that it is connected to its loom correctly on the engine bulkhead... could also be just a loose connection...

good luck

 

[dan1]

sorry, just reading through..... vag-parts... derrrr not vag-com!!!!!

Now that would be cool, find the fault and it automaticlly orders the correct part for you!!!