Mk6 2005 2.4 90ps P0149 and P1564 codes with NO knocking!

[VanDunk]

I have trawled through posts re P0149 (Fuel pump timing error) and P1564 (FIP requesting reduced fuelling mode) but don't seem to have found an answer for this one.

My Mk6 05 2.4 90ps LWB RWD is throwing up the P0149 (Fuel pump timing error) code and going into "limp" mode.
It sounds sweet as can be, runs fine with NO knocking/rattles and starts first turn of key.

It will make decent power if the ignition is briefly turned off/on whilst driving or from start-up, until P1564 FIP requesting reduced fuelling mode occurs after a very short time.

It has only done a genuine 32k with one previous owner.
Has always seemed a bit lacking power (running out of puff around 3000rpm and lacking further throttle response) since I've had it.
Rear axle ratio was changed to 4.63 from 5.13 last year as it was a bit of a screamer.

New fuel filter was fitted during service early last year (Mann WK8157).
It had a new clutch, DMF and crank seal about 1k ago as seal was leaking oil into the bell housing and the DMF was well on it's way out.
Only mention the clutch because I've seen mention about engines being turned in reverse direction during replacement causing timing issues with chain jumping.

Any ideas before I spend ££££ on diagnostics/parts?
Cheers

[paul2012]

12/6/04 Noisy engine, reduced power, DTC's P0149 and P1564 set
64/2004 Should a customer express concern that the engine is noisy and there is reduced power, the probable cause is the fuel injection pump timing solenoid. With this concern, diagnostic trouble codes (DTC) P0149 and P1564 will be set in conjunction with a noisy engine. To rectify this concern, a new fuel injection pump timing solenoid should be installed.

As listed here viewtopic.php?f=31&t=154710#p1304327

[VanDunk]

What about codes when customer doesn't have a noisy engine though??
This is my problem as engine sounds fine.
Confused.com

[Crankshaft]

I have exactly the same issue with my 2001 mk6 2.4 90ps. Checked on edit and mine also has the 4.63 axle.

Van runs well, only had diesel knock for a split second when cold twice trying to pull up the hill from work in too high a gear.
It does run out of power at about 3k unless I've stopped the engine and restarted it warm, then it flies in comparison.

The same p0149 timing fault and p1564 reduced fuelling requested keep coming up too.

Yesterday I bought the timing solenoid kit from my local dealer (£176) and hope to get it installed over the next week.

I'll let you know how I get on, fingers crossed.

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[VanDunk]

Would be really interested to see if your solenoid fixes it.
Hopefully it does as it's a bit of a odd one without all the usual symptoms
Cheers

[Frag]

You can get those 2 codes from pump timing being slightly out,
There's another tsb for same symptom,usually after fuel pump replacement,
Due to 'slack' in chain between pump and crank sprockets.
Van will be in limp mode with those codes.

[Crankshaft]

Spent most of the day working on the solenoid swap, egr and inlet off no problem, however I can't get the solenoid to shift without destroying the pump.

Ordered the laser timing kit so I can get the pump out, should be here Sunday afternoon.

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[Crankshaft]

Progress in pictures





As you can see from the last one, access isn't fantastic.

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[Crankshaft]

Job done
Took me all day and the solenoid was well corroded into the pump, needed lots of plus gas as well as plenty of heat and a good walloping with a hammer and 2 small chisels.
Cleared the fault codes and went for a 50 mile drive, codes haven't come back and it pulls like a steam train in comparison.

Well chuffed.

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[Crankshaft]

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[Crankshaft]

Don't forget the small o-ring that sits deep inside the body


New solenoid fitted, I've smeared silicone grease on the body to try and prevent sticking should it need to come out again.


Wiring crimped and heat shrink shrunk. I've also wrapped the joint in self amalgamating plumbers tape just to be sure no damp gets in.


I bought the laser 4066 timing kit and found a few niggles, the crank timing pins have a 90 degree bend in them but are too long, the bend fouls on the bulkhead.
I had to heat them up, straighten the handle then re-bend them further down the shank to shorten them.
Also the t40 torx bit was such a snug fit through the pump sprocket I couldn't get it to fit into all 3 bolt heads without moving the crank back and forth, turned 0.5mm off it in the lathe.

I found that my pump has been off before and the timing was out, could see the original witness marks on the sprocket from the 4 bolt heads, this one was timed up a few degrees advanced.
On refitting I've timed it properly and it's almost on the original witness marks.

I don't know what I've done but when starting it's sluggish to turn over, like the battery is flat, even though it's at 12.95 volts. I'll recheck the starter terminals and earth strap.



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[VanDunk]

Good Sunday's work there.
Do you think the pump timing being off could have been the whole problem or the solenoid was also at fault?
Seems like its fixed it if you've done 50 miles without the dredded P0149!
Keep us posted on the performance.

[Crankshaft]

Not sure if the timing being out played a part or not. A few times recently I found that if the revs were kept below about 3000rpm a short journey could be done without triggering the p0149.

Judging by the state of the valve I'm inclined to think this was the main cause all along.

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[VanDunk]

Thinking of getting mine done now.
Is the pump torx tool just a long reach t45 bit? Length?
Was looking at a kit on ebay but doesn't seem to comewith the torx bit like the Laser 4066, but it's a lot cheaper

[Crankshaft]

The torx bit in the laser kit is a t45, 75mm in length

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