Audi A3 8P 2.0t fsi low fuel pressure issue

[MNR]

Evening all
I bought a 2005 Audi A3 8P 2.0t fsi engine code AXX with 230k km on and noticed a water leak on one of the steel pipes that I end up replacing as the previous owner just closed the hole with Pratley steel but the car was driving fine. While replacing the steel pipe I decided to strip off the intake and do a DYI carbon clean and sent the injectors in for a recon as the looked filthy and decided to change the cam follower, the old one did not look bad but just ended up replacing it anyway and the cam lobe does not look like it has wear on it, i also had to replace the low pressure sensor connector on the fuel rail as it was very brittle and broke when I took the connector off. I also did a full service Oil, oil filter, spark plugs, fuel filter(made sure its a 6.6bar), air filter ETC. I also decided to replace the PCV valve with a OEM one and also replaced all the gaskets from the parts I took off. After all of this I keep getting a P1063 fuel pressure regulation value below lower control limit below is the trouble code OBDeleven gives me.

01 Engine

System description: 2.0l R4/4V TFSI G00
Software number: 8P0907115D
Software version: 0070
Hardware number: 8P0907115D
Serial number: AUX7Z0E5FNS0GA
Long coding: 0103001018070160

Trouble codes:
P1063 - Fuel Pressure Regulation Value below lower control limit Lower limit not reached
static
Priority: 0
Frequency counter: 6
Driving cycle: 255
Mileage: 230506 km

When I run logs on the car I can see the car is demanding 50 bar it idle but only gets 30 bar but when I drive the car the demanding and actual value is almost the same. It also seems like the previous owner changed the HPFP with a Pierburg HPFP not sure if the old one just failed or what the reason was but wat baffles me is I have a spare OEM HPFP I got from my friend that had a failed cam follower but the top sensor is fine and when I change the top sensor to the one my friend gave me the car is fine the actual and demanding values is spot on until I switch off the car and start again then the same P1063 error comes back and can see the actual and demanding values has a +- 20bar difference. When I then change back to the Pierburg top sensor the car is also fine but then when I switch the car off and start the car the P1063 error comes back?

Not sure what direction to go now? Can it be the HPFP or LPFP?

[MadVillain]

Check fuel filter under car

[MNR]

Check fuel filter under car

Thanks i have changed the filter already with the 6.6 bar filter but seems like the car just fixed itself will just monitor the fuel pressure.

[MNR]

Over the last month of driving the car, all is fine except the P1063 error keeps coming back in the morning when the car is cold and then clears itself when the car has heated up but the car is a bit jerky when the error appears. This is only in the morning as I leave home at around 5 am and when I leave the office at around 3 pm the same error does not appear.

[MNR]

Date: 2023-04-21 07:53

VIN: WAUZZZ8P66A029053
Car: Audi A3
Year: 2006
Body type: Hatchback
Mileage: 231430 KM

---------------------------------------------------------------
Fault
Control unit: 01 Engine
Active faults: 1
Inactive faults: 0
System description: 2.0l R4/4V TFSI G00
Software number: 8P0907115D
Software version: 0070
Hardware number: 8P0907115D
Serial number:
Faults:
P1063 - Fuel Pressure Regulation Value below lower control limit Lower limit not reached
Intermittent
Priority: 0
Frequency counter: 1
Driving cycle: 255
Mileage: 231135 km
Date: 2023-04-13 05:15:20


Mileage: 231130 km
Date: 2023-04-13 05:21

---------------------------------------------------------------
Fault
Control unit: 08 Air Conditioning
Active faults: 0
Inactive faults: 0
System description: KlimavollautomatH16
Software number: 8P0820043H
Software version: 0200
Hardware number: 8P0820043H
Hardware version: 000
Serial number: 8P0820043H
Faults:
No trouble codes found

Mileage: 231130 km
Date: 2023-04-13 05:21

---------------------------------------------------------------
Fault
Control unit: 09 Central Electrics
Active faults: 1
Inactive faults: 0
System description: Bordnetz-SG H36
Software number: 8P0907279F
Software version: 1201
Hardware number: 8P0907279F
Hardware version: 063
Serial number: 00000002048825
Faults:
02195 - Instrument panel lighting dimmer switch Open circuit/short circuit to ground
Intermittent
Priority: 5
Frequency counter: 13
Driving cycle: 231
Mileage: 231109 km
Date: 2023-04-11 05:20:00


Mileage: 231130 km
Date: 2023-04-13 05:21

---------------------------------------------------------------
Fault
Control unit: 15 Airbag
Active faults: 0
Inactive faults: 0
System description: Airbag 9.41 H11
Software number: 8P0959655H
Software version: 3520
Hardware number: 8P0959655H
Serial number: 0037W000AHYH
Faults:
No trouble codes found

Mileage: 231130 km
Date: 2023-04-13 05:21

---------------------------------------------------------------
Fault
Control unit: 16 Steering Column
Active faults: 0
Inactive faults: 0
System description: Lenksäulenmodul H34
Software number: 8P0953549E
Software version: 0070
Hardware number: 8P0953549E *
Faults:
No trouble codes found

Mileage: 231130 km
Date: 2023-04-13 05:21

---------------------------------------------------------------
Fault
Control unit: 17 Dashboard
Active faults: 0
Inactive faults: 0
System description: KOMBIINSTR. VDO H80
Software number: 8P0920930T
Software version: 0410
Hardware number: 8P0920930T
Serial number: 2245ED03000601
Faults:
No trouble codes found

Mileage: 231130 km
Date: 2023-04-13 05:21

---------------------------------------------------------------
Fault
Control unit: 19 Gateway
Active faults: 1
Inactive faults: 0
System description: Gateway H10
Software number: 1K0907530F
Software version: 0120
Hardware number: 1K0907951
Serial number: 28001056248458
Faults:
01304 - Radio No signal/communication
static
Priority: 2
Frequency counter: 23
Driving cycle: 191
Mileage: 231109 km
Date: 2023-04-11 05:20:43


Mileage: 231130 km
Date: 2023-04-13 05:21

---------------------------------------------------------------
Fault
Control unit: 25 Immobilizer
Active faults: 0
Inactive faults: 0
System description: KOMBIINSTR. VDO H80
Software number: 8P0920930T
Software version: 0410
Hardware number: 8P0920930T
Serial number: AUX7Z0E5FNS0GA
Faults:
No trouble codes found

Mileage: 231130 km
Date: 2023-04-13 05:21

---------------------------------------------------------------
Fault
Control unit: 42 Driver Door
Active faults: 0
Inactive faults: 0
System description: Tuer-SG 020
Software number: 8P0959801H
Software version: 0070
Faults:
No trouble codes found

Mileage: 231130 km
Date: 2023-04-13 05:21

---------------------------------------------------------------
Fault
Control unit: 44 Steering Assistance
Active faults: 0
Inactive faults: 0
System description: EPS_ZFLS Kl.5 D04
Software number: 1K2909144J
Software version: 1606
Faults:
No trouble codes found

Mileage: 231130 km
Date: 2023-04-13 05:21

---------------------------------------------------------------
Fault
Control unit: 46 Comfort System
Active faults: 1
Inactive faults: 0
System description: KSG H03
Software number: 8P0959433
Software version: 0040
Faults:
01134 - Alarm horn
static


Mileage: 231130 km
Date: 2023-04-13 05:21

---------------------------------------------------------------
Fault
Control unit: 47 Sound System
Active faults: 1
Inactive faults: 0
System description: AB2 SUBWOOFERBOXH25
Software number: 8P3035382
Software version: 0160
Hardware number: 8P3035382
Serial number: 10000001264385
Faults:
02247 - Subwoofer Open circuit
static
Priority: 5
Frequency counter: 1
Driving cycle: 190
Mileage: 231109 km
Date: 2023-04-11 05:20:43


Mileage: 231130 km
Date: 2023-04-13 05:21

---------------------------------------------------------------
Fault
Control unit: 52 Passenger Door
Active faults: 0
Inactive faults: 0
System description: Tuer-SG 020
Software number: 8P0959802H
Software version: 0070
Faults:
No trouble codes found

Mileage: 231130 km
Date: 2023-04-13 05:21

[PapaJo]

From this:
“ Faults:
P1063 - Fuel Pressure Regulation Value below lower control limit Lower limit not reached
Intermittent”

Seems you have pressure regulation issue and possible intermittent stuck fpr regulation in the fuel pressure relief route.

The radio and subwoofer errors are likely due to radio removed or afternarket radio installed or a bad earth on radio circuit wiring.

Check that all connector pins on the gateway module as it is linking all the modules together to ecu and sub systems.

[MNR]

Hi PapaJo

Thanks for the reply

Hope the caddy work is going good? My fox is standing waiting for some funds to get it retuned etc

The Radio\subwoover and Instrument panel lighting dimmer switch error is understood as the OEM radio has been removed and replaced with an aftermarket radio by the previous owner and I think he also messed up the subwoofer and the dimmer switch is not working at the moment will sort this out at a later stage as I just want to get the car reliable first.

Will further investigate the fuel pressure relief route just not sure what else to look for as I did replace the fuel filter with the correct 6.6 bar version, I did read that this is a common issue where people install the incorrect fuel filter.

[MNR]

Still get the same error but noticed now it's only when driving on the freeway, doing short trips to work and back the car is behaving.

Think maybe the HPFP is acting up or the cam got damaged previously causing the HPFP not to keep its pressure.

[MNR]

To whoever have this issue i pulled the trigger and replaced the intake cam and now the error stays away.

Next up is to find a whistle sound that the car makes at 3000rpm.

[PapaJo]

To whoever have this issue i pulled the trigger and replaced the intake cam and now the error stays away.

Next up is to find a whistle sound that the car makes at 3000rpm.

One thing fixed and the next challenge is there.

Most likely a vacuum leak. Check the secondary airpump piping.

[MNR]

Thanks also think it's a vacuum leak somewhere.
I built a DIY smoke machine with a old soldering iron and some baby oil with a cloth and a cheap pump I bought on Takealot but not seeing any smoke coming out anywhere but will go through all the vacuum pipes to see if I can find something. The old owner just glued pipes together when they broke .

[PapaJo]

Thanks also think it's a vacuum leak somewhere.
I built a DIY smoke machine with a old soldering iron and some baby oil with a cloth and a cheap pump I bought on Takealot but not seeing any smoke coming out anywhere but will go through all the vacuum pipes to see if I can find something. The old owner just glued pipes together when they broke .

Might need to start at those glued pipes.

[MNR]

Yip just a struggle with some pipe's not being made or discontinued so replacing them with custom silicone vacuum pipes. Especially the vacuum pipe going from the vacuum pump to the intake and then splits off to the break booster etc. This is the first one I replaced with silicones but still getting the whistle sound. thinking of tracing all the pipe one by one.

[MNR]

Found a vacuum leak when the car is hot on one of the pipes going to the PCV valve, went and bought a replacement pipe but ended up using the OE one with new O rings as the non-OE replacement keeps popping off when going into boost. Now there is no leak but the whistle sound is still there.. seems like it's coming from behind the engine. I sure hope it's not turbo...

[PapaJo]

Check if there is a thin pipe connected to the nipple on the compressor housing inlet that goes up towards the turbo inlet rubber pipe.

[MNR]

I did see a thin pipe coming from the turbo and connected to the tappet cover seem's like it's been replaced before will see if I can find any cracks on it.