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Seat Inca 1.9 AYQ 2004 - Code P1563 quantity adjuster lower limit - Fixed #

Posted by Trevor Kelleher on April 21, 2016, 7:54 pm

Year of Manufacture *: 2004
Engine Size and Code *: 1.9
( Optional ) Scanner Used: vcds

Evening everyone,
We got a seat Inca 2004 SDI, in last Monday, engine code AYQ its the older engine with the Bosch injector pump,
This came in as a non start and was after having 2 injector pumps installed before hand, in the hope of getting it up and running,

codes were,p1563 quantity adjuster lower limit, and, 01282 intake flap valve n239 , short/open circuit,

What i have tested are,
compression which is good,
It runs well on sniff,
I replaced relay 109 with a known good one,
egr blocked off,
timing which was perfect,
wiring between ecu and injector pump pens 1 to 8 load tested with a 55w bulb no problem found, pens 9 and 10 were not shown on any of the 3 wiring diagrams i have,pen 10 is a good 12v supply, i am not sure where the wire coming from pen 9 is going do!!!!
Crank signal is showing as it should, when i compared the scope trace with a known good one,
300 cranking rpm
Ecu replaced with a known good 1 which a had for testing,
And power and ground supplies to the ecu load tested perfect too
There is 1 good ground supply at the injector pump and 3 good power supplies which tells me the relays are doing there job,,
So this is as far as i have gone with this,
Any ideas would be welcome,

Re: seat

Posted by Matt Booth <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3028' width='330' height='300' border=0 style='border:none;'> on April 21, 2016, 8:42 pm, in reply to "seat"

Have you tested the fuel shut off valve on the pump? Can't remember how accessible it is but you can either check for a feed to it, activate it on VCDS or check for a feed at pin 8.

9 and 10 are for the 'commencement of injection valve'. Feed on 10 and earthed by 9.

Also, check for a feed at pin 4 of the intake manifold flap as this is the same feed used for the metering adjuster and would explain both codes

Matt

Re: seat

Posted by tony bickers <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5143' width='330' height='300' border=0 style='border:none;'> on April 21, 2016, 10:22 pm, in reply to "seat"
Anthony Bickers

How much does your customer want to spend??, I had one of these a few years ago, went to scrappie as uneconomic to repair, same engine, worth nothing !!

Re: seat

Posted by Trevor Kelleher on April 22, 2016, 8:28 pm, in reply to "Re: seat"
Edited by board administrator April 25, 2016, 7:31 am

I just checked all the wires (1 to 10) between the ecu and injector pump this evening and they all tested good,
There all load tested with a 55w bulb,checked for short to ground and short to plus,just to be sure,

Pin 5,8 and 10 have a good power supply,

and pin 4 at the intake manifold flap has a good power supply as well,

The pump and the shut off valve clicks as it should when the key is switched on,

Re: seat

Posted by Trevor Kelleher on April 22, 2016, 8:32 pm, in reply to "Re: seat"
Edited by board administrator April 25, 2016, 7:31 am

The customer is not going to spend too much on this Tony,i told him to drop it down and i will have a look at it during the evenings and see how it goes,
He is a elderly man who cant afford a new van and if i can get it running easy enough the van would last him away for years,

Re: seat

Posted by andrew pethig <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3731' width='330' height='300' border=0 style='border:none;'> on April 22, 2016, 8:48 pm, in reply to "seat"

Re: seat

Posted by tony bickers <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5143' width='330' height='300' border=0 style='border:none;'> on April 22, 2016, 9:29 pm, in reply to "Re: seat"
Anthony Bickers

Hi Trevor, you have already racked some hours on this one, surprised the diesel experts here have not commented, the one I had was an immobiliser corruption which I suspect was caused by trying to jump start. One thing you could try is cut off the anti tamper shield over the "stop solenoid", take the plunger out and see if it starts,good luck mate

Re: seat

Posted by Matt Booth <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3028' width='330' height='300' border=0 style='border:none;'> on April 23, 2016, 2:23 am, in reply to "Re: seat"
Matthew Booth

Have you tried running a clean fuel supply directly to the pump? I use a bmw pre-supply pump to aid air removal at the same time.

Have you checked the pumps ability to suck fuel, or cracked an injector to see if there's any fuel delivery (doubtful).

Matt

Re: seat

Posted by Trevor Kelleher on April 23, 2016, 10:31 am, in reply to "Re: seat"
Edited by board administrator April 25, 2016, 7:32 am

The immobliser is switching off ok on this one Tony,they do give a lot of trouble on these alright do,

Matt,
I ran a direct supply of good diesel through the pump until it was returning through the back flow and it made no attempt to start.

I would be surprised if it them injectors are opening,there is no smoke coming from the van when its turning over,

I could try a test injector on the pipe just to see do,

My neighbor have the same van i could try his ecu on this and see what happens the other garage already put 2 injector pumps on this,
There cant be much more (that i can think of left)unless i am missing some thing

I appreciate your taughts on it, thanks

Re: seat

Posted by Trevor Kelleher <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3963' width='330' height='300' border=0 style='border:none;'> on June 2, 2016, 11:32 pm, in reply to "Re: seat"
Trevor Kelleher

I took out the heater plugs and turned over the engine first thing to see if the injectors were actually injecting diesel and sure enough there was plenty diesel vapor spraying from the plug holes,

I had a good crank signal, the injectors were firing,glow plugs working,good compression.so i said is there any chance the timing could be out!!

I had to remove the air intake manifold then the top clover and got out my timing tools and check it,,

Sure enough the cam timing was out by 180 deg.

When it ran on sniff,( it can if the cam timing is exactly out by 180 deg) and when i was told the cam timing is 200% correct i over looked it!!

I should have known better at this hour of my life not to trust no ones work unless i see it done first hand myself,

Another day another lesson,

Many thanks to you all do for your help full replies,

Re: seat

Posted by Alan Lange <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3293' width='330' height='300' border=0 style='border:none;'> on June 3, 2016, 8:33 pm, in reply to "Re: seat"
Alan Lange

Hello Trevor, just a thought but if you turned the engine over one turn on the crank your cam timing would be spot on (why you had good compression) so it would appear your pump timing was 180 degrees out. Same result though.

Fixed #

Posted by Trevor kelleher on May 24, 2017, 9:59 pm, in reply to "Re: seat"
Edited by board administrator May 25, 2017, 1:40 pm

This is fixed,
As above the cam timing was out by 180deg,

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