MK5 GTI - FUEL CUTS P1063-002 Control range not reached

[GT 5IDHU]

Hi all,

Hoping somebody can help.
My gti has a stage 1 RTECH MAP

What started off as a simple problem and what i thought was a simple fix has turned into a mystery.
I started having fuel cuts and hesitation above 3k in 3rd/4th gear. So when I'm on the motorway flat out the car just stopped at 120mph and i had no control of the pedal, wait 10 seconds and car comes back to me.

Mechanic diagnosed the problem as the sensor on top of the HPFP was cracked. So after buying a HPFP off this forum with a 'perfect sensor' it arrived with a cracked sensor (you know who you are).
Went to TPS bought a brand new HPFP and cam follower. Noticed that my cam follower was not worn out as they normally do but more indented, as if someone had punched the face of it?? Mechanic has never seen one like that.. Checked the cam lobe and still seemed smooth. So after all that, took it for a drive, seemed fine. Car was pulling like normal. Few days later the problems comeback..
P1063-002 CONTROL RANGE NOT REACHED. since then i have changed the fuel filter and check the cam follower again and it seems perfect.

What can i do next?
Im seriously gutted about this, as I'm now putting the car back to stock and having to sell it due to getting married!
If i could fix the car, i would love to keep it. Im guessing the car will be fixed if i take the map off as its not asking for too much fuel that way.

Please help
Thanks
GT

[ROH ECHT]

It would help if you had some data to look at...but knowing what it's doing says what it could be.

If the fuel filter was replaced recently...was it the correct 6.6 BAR regulator filter? Because there is a 4.0 BAR regulator filter that gets confused with it and can be installed. The pressure it regulates is stamped on this end: https://changegears.files.wordpress.com/2011/09/dsc_2327.jpg?w=869&h=580

If the cam follower's face had its black coating and was dented on its face...something got between the lobe and the CF and forced the pump's drive rod into the hpfp farther than it should've and cracked the pressure regulator. Wouldn't surprise me if you find bits of crud inside the cam-chain tensioner cover.

How long you had it? Is it possible the follower had been worn through before while under different ownership? Did you see all service records?  If you've owned it since new...perhaps the rings inside that cover are gone to pieces and caused the damage: https://c1552172.ssl.cf0.rackcdn.com/590753_x600.jpg  If pn is needed: https://www.ecstuning.com/ES2726697/?gclid=CjwKEAjw5pKtBRCqpfPK5qXatWYSJABi5kTxAEu3Fro_PDcaoBk1JN-5rCM1m1FuG671w5eFAzatuRoCb3Pw_wcB

The G410 is the most likely culprit...mounted on the top of the hpfp, it reports low fuel pressure. When you replaced the hpfp my guess is that the G410(pn:  06E 906 051K) was reused.

[GT 5IDHU]

Hi mate
Thanks for the reply
The fuel filter was changed only this week to rule it out. It was a genuine gti one from dealer.

Yes the cam follower had a bit of black coating left but was if someone had hit it with their knuckle
Im pretty certain the engine cover broke the pressure regulator as the mounting bracket was loose and banging off the top of the HPFP.

Ive had the car almost 3 years, I've always checked the cam follower whenever the car goes in to the garage for something, as a precautionary measure. Service record is good all from VW Main dealer.
What is the G410 mate?
The new hPFP came with everything including the sensor on top. Part number ended in M though?

[ROH ECHT]

Hi mate
Thanks for the reply
The fuel filter was changed only this week to rule it out. It was a genuine gti one from dealer.

Yes the cam follower had a bit of black coating left but was if someone had hit it with their knuckle
Im pretty certain the engine cover broke the pressure regulator as the mounting bracket was loose and banging off the top of the HPFP.

Ive had the car almost 3 years, I've always checked the cam follower whenever the car goes in to the garage for something, as a precautionary measure. Service record is good all from VW Main dealer.
What is the G410 mate?
The new hPFP came with everything including the sensor on top. Part number ended in M though?

The last letter in a part number is just the revision it is...so as new revisions are distributed the last letter will always go through the alphabet.
The filter with the 6.6 BAR regulator and the 4.0 one both come from the dealer and they make mistakes sometimes handing them out is what I have read from others. Given that the CF was worn and not punched...I'd stick with the most likely suspect being the G410 is as I posted before...links in the previous post will give you the part number. One more thing to try is...unplug the MAF sensor and see if it is corrected in the way it should run. If it does run better...replace the MAF.

[GT 5IDHU]

Hi mate
Thanks for the reply
The fuel filter was changed only this week to rule it out. It was a genuine gti one from dealer.

Yes the cam follower had a bit of black coating left but was if someone had hit it with their knuckle
Im pretty certain the engine cover broke the pressure regulator as the mounting bracket was loose and banging off the top of the HPFP.

Ive had the car almost 3 years, I've always checked the cam follower whenever the car goes in to the garage for something, as a precautionary measure. Service record is good all from VW Main dealer.
What is the G410 mate?
The new hPFP came with everything including the sensor on top. Part number ended in M though?

The last letter in a part number is just the revision it is...so as new revisions are distributed the last letter will always go through the alphabet.
The filter with the 6.6 BAR regulator and the 4.0 one both come from the dealer and they make mistakes sometimes handing them out is what I have read from others. Given that the CF was worn and not punched...I'd stick with the most likely suspect being the G410 is as I posted before...links in the previous post will give you the part number. One more thing to try is...unplug the MAF sensor and see if it is corrected in the way it should run. If it does run better...replace the MAF.

Thats great mate, I'm talking about a different sensor on the top of the fuel pump. The G410 is the thrust sensor? That has not been changed, so are you saying my old G410 wont work with my new revision hpfp?

i will try the man tonight
thanks

[ROH ECHT]

Might be called that...but the G410 detects low pressure feed to the hpfp. The one on top is the N276(fuel pressure regulator). If the feed pressure isn't there...or the sensor isn't detecting properly...then shut down occurs and doesn't allow it to perform at its maximum.
http://i955.photobucket.com/albums/ae31/ciprianpatulea/N276.jpg

The N276 comes with the hpfp and cannot be obtained separate from the hpfp...but the G410 does not come with the hpfp and was likely swapped from the old one to the new hpfp.
http://www.uspmotorsports.com/images/P/06F%20127%20025K.JPG