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Discussion Starter #1
Hi, this is a lengthy one, but hoping for assistance. A 2008 Vectra C DTH was brought is as a non starter,timing had been undone, and pump taken out, among other things.
The history was petrol/gasoline was mistakenly added to the car by by mistake. The tank was cleaned and since then, the car started what they called a misfire. Their local garage took it apart, and then deserted it in the state I found it, four months later.

I redid all the stuff, including timing, but there is one HUGE problem, 'fuel rail pressure low' among many other codes P0380, P0001, P0190.
The real problem is there is no fuel in the common rail, but the pressure in the return rail is what I would love to have in the common rail. In short, there is high fuel pressure that you cannot stop with your finger on the two top outlets of the high pressure pump, but the down one which supplies fuel to the common rail has nothing, but only a drop of fuel.
This is my first diesel to deal with, any pointer will be very much appreciated.
 

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No, it is the same pump, but it was openned up at an attempt to fix it
Unless your trained & qualified to open up a high pressure pump your best not to attempt meddling.
Try and source a new secondhand pump you know is working.
Many on here have taken high pressure pumps apart only for their car to never run again.
 

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No, it is the same pump, but it was openned up at an attempt to fix it
Petrol going through a high pressure diesel pump will kill it.
As Fred says, rebuilding these pumps is a specialist job.
You need to get a replacement and fit it.
 

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And dont remove the high pressure lines with the engine running, if the fuel hits your skin at the pressures it runs at it will penetrate your skjin and go into your blood stream, it wont end well.
I've just read the original post again, and, as Andyl says, DO NOT try to test pressures by putting your finger over pump outlets, or loosen high pressure lines with the engine running. If the diesel penetrates your skin, it can be fatal!
 

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Discussion Starter #12
Well, so as my pump arrived, I installed it on the Vectra and it just behaves like the old one.
The pressure in the return line is what I would love to have in the supply line, unfortunately, there is no fuel coming into the common rail.
When I turn on the ignition, the comes some fuel and it builds some pressure in the common rail, but when I try to crank, the fuel supply is cut of, and only fills the return line.
The only DTCs I have in the engine are fuel rail pressure related, as well as glow device error.
The big question I have, I have read somewhere that I need to program the High pressure pump, if true, how do I achieve that? I have Tech2.
 

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When the replacement pump came, did it have a suction control valve fitted, or have you used the one off the old pump?
 

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Discussion Starter #17
No programming needed on the pump,.... have you tried clamping off the return valve on the opposite end of the rail, then see what pressure you get at ignition on.
The return valve had been stripped of its internal components by a previous technician, I cannot figure out why.
Anyways, blocked the return and the engine roared to life to the joy of the owner who had it parked for nearly two years.
So, off to eBay to search fora working return valve

Thanks. issue resolved.
 
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