Sugar Contamination Nightmare

Chuck Diagnostician Sylvania, Georgia Posted   Latest   Edited  
Question
Driveability
2016 BMW 320i 2.0L (N20B20A) 6-spd (GS6-17BG)
Enters Limp In Mode Under Heavy Acceleration And Set Code 110001 & 11A031

Vehicle presented to a body shop with evidence of sugar contamination. Low pressure electric fuel pump was replaced, fuel lines from tank were flushed and fuel tank cleaned prior to being referred to our shop. Codes presenting upon arrival and prior to any other repairs were 11A031-low psi electric pump, 110001-cylinder injection shutdown, 11A002-fuel high pressure plausibility, low psi intermittent. Vehicle runs great during a slow, steady acceleration. On a heavy acceleration, vehicle would set codes & go into limp in mode. Cleared codes and vehicle would run fine until another heavy acceleration. Since this was an insurance job, decision was made to replace all components coming in touch with the sugar contamination. Therefore, we replaced the high side fuel pump, fuel rail pressure sensor, and all injectors. Still have the same codes and same symptoms. Insurance is now out of the picture feeling like they have met their responsibility. The customer has hired us to fine the problem. 

I have tested the following:

-power, ground, & current pattern of the electrical fuel pump in the tank during the "event". Did not loose voltage nor ground. Amperage was 3 amps. 

-the low side fuel pressure during the "event" remains a steady 85 psi

-scoped power, ground, & signal of fuel rail pressure sensor. Reference voltage & ground are with normal limits. Sensor signal showed a drop of pressure to roughly 30 psi which lasted about 1.2 seconds. The signal then went back to normal pressure but by then the vehicle was in limp in mode. Also caught on scan data from one frame to the next, 3 seconds apart, the high side psi dropped from 2899 psi to 30 psi. The electric fuel pump activation shows 14.9 gal​.​hour & 15.61 fuel pump status on both frames. Terminal 15 status on, both frames. Terminal 87 status 14.7 V on both frames. 

Throw me some ideas please.....and thank you!

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Nelson Manager
Commack, New York
Nelson Default
   

Hey Chuck, One thing stuck out to me. You stated that you have a steady 85 psi at the low side fuel pressure. How was this checked? Mechanical fuel pressure gauge or scan tool? This engine does not have a low pressure fuel sensor. The reading seen via scan tool is calculated by the DME. I highly suggest hooking up a mechanical gauge if you haven't done so already and redo your testing.

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Chuck Mechanic
Sylvania, Georgia
Chuck Default
 

Nelson, I was using the Hickok Pressure Pro software and plumbed in at the disconnect at rear of engine. One day I'm going to get my grand kids to teach me how to up load all of the captures I have . I have fought similar issues on an Isuzu diesel before and found bad wiring but all connectors and wiring looks pretty good. Plan to scope the quality control valve of the high pressure pump

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Nelson Manager
Huntington Beach, California
Nelson Default
 

Great. That would be amazing if you could post up those captures! What is the nominal high fuel pressure value the DME is asking for when the "event" occurs? Or in other words, what is the DME requesting from the HDP when the event occurs (in pressure)? Did you get around to scoping out the quality control valve at the HDP?

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Dean Owner
Albany, New York
Dean Default
   

How many miles on this car? Also, did you hook up ISTA and start a test plan?

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Mark Manager
Boston, Massachusetts
Mark Default
 

Good evening Chuck, I'm working on a 2014 GMC Arcadia 3.6 L GDI with Heavy sugar contamination fortunately I got the car early in the insurance/repair process, Replaced tank , low pressure pump , high pressure pump , all injectors , high pressure lines , and high pressure fuel rails , removed and flushed the low pressure lines with hot water. Codes before repair just a p0300 owner had been

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Paul Technical Support Specialist
Lefkosia, Cyprus
Paul Default
 

Hi Chuck, First question i have for you, is why the vehicle was in a body shop in the first place. To my experience so far, a vehicle that was at a body shop, and later on has any sort of issues, is always tied to wiring issues and misplacement of connectors or components in general. Was the car involved in a crash? If yes, where was the damage located and how bad was it? Any ideas of where

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Chuck Mechanic
Sylvania, Georgia
Chuck Default
 

Paul, no crash, no body damage. Domestic dispute which lead to third party vandalism. ( draw your own conclusion) Car was keyed and sugared. Body shop installed BMW pump, I have installed all Bosch parts. I even installed a second rail sensor knowing it most likely would not help. VIN is WBA8E1G51GNT335421 production date 10/15. I will be looking into your suggestions today. We do carry BG

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Paul Technical Support Specialist
Lefkosia, Cyprus
Paul Default
   

Chuck, you are right. To me a car that has been to a body shop means that a crash was involved. At least this is what happens in my area. Plus body shops in my area deal with nothing else except from body repairs and painting. Ok, so 11A031 does return with: Secondary fault caused by an empty fuel tank Perform a function test of the electric fuel pump. Check the lever sensor Check whether

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Mario Diagnostician
Weston, Florida
Mario Default
 

I don't know what other option you would have other than using a high pressure fuel gauge(VAS 6394) to confirm a pressure sensor issue. Hoping someone could chime in with other ideas as to confirming or ruling out faulty sensor.

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Chuck Mechanic
Sylvania, Georgia
Chuck Default
 

"Hail Maryed" a second rail sensor but no help.

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Dean Owner
Albany, New York
Dean Default
 

How many miles and do you have ISTA?

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Chuck Mechanic
Sylvania, Georgia
Chuck Default
 

Sorry Dean, I thought I responded to you last night but must not have pressed "POST". The car has 55668 miles on it. I do not have ISTA but Identifix has sent me some good information pertaining to the system. While I feel sure in isn't the same as a test plan, it is full of specs, locators and diagrams. Just using a pragmatic approach in the absents of tooling.

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Dean Owner
Albany, New York
Dean Default
 

No troubles Chuck. That's really low miles, so cam wear on the high pressure pump would not be the issue. The reason I asked about ISTA is because it will develop a test plan and find a direction for you to go in. Its really intuitive.

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Bentley Manager
San Diego, California
Bentley Default
 

As stated verify low pressure fuel psi with a gauge. If ok, test high pressure psi with a gauge. If high pressure is the issue check the pump roller/plunger and cam lobe for damage since pump is new.

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Chuck Mechanic
Sylvania, Georgia
Chuck Default
 

plunger looked good

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Chuck Mechanic
Sylvania, Georgia
Chuck Default
 

Update, I have checked and rechecked all of the suggestions and still no answer. Did however fine more questions. The rear electronics module had two codes for level sensors 804951 and 804954, which I cleared have they have not come back. One of the trouble shooting steps of 11A031 states to check the level sensors. Then I found a bulletin B621817 where instrument cluster software can cause the

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Paul Owner/Technician
West Collingswood, New Jersey
Paul Default
 

Hi Chuck , I have been the post very knowledgeable guys been replying. is there a FPR on this system. I know 1 thing working on CRD engines I have learned even though you replace all the parts until you reset the adaptations all the components, new parts means nothing. I do 90% work on sprinter when ever we have contamination fuel issue. FPR always go down 1st . vehicle only would looses power

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Bentley Manager
San Diego, California
Bentley Default
 

I may have missed it, was the high pressure fuel regulator replaced?

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Chuck Mechanic
Sylvania, Georgia
Chuck Update
   

Not sure where to enter the fix to this Sugar Nightmare. I attached some pics above. I now have a "sweet ending". The test results led me back to removing the fuel pump supply line. Blew thru the line and collected additional sugar. The pics of the fuel show there are still a few granular's left in the tank. Upon removing the fuel supply line on the high pressure fuel pump, I found three

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Chris Diagnostician
Lansdale, Pennsylvania
Chris Default
 

Thank you for the update Chuck. I know myself, and I'm sure others, really appreciate the closure, even if we weren't able to help in a particular instance. This is yet another one to go in my memory. I appreciate the time you put in and hope to continue seeing more.

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Shane Owner/Technician
Merced, California
Shane Default
 

Thanks for updating with the fix. I had a car with the exact same problem and you just solved the issue I've been chasing for the last week. On mine the dealer had replaced the tank and HPFP but apparently forgot to flush the lines.

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