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Thread: Z22YH fault code 1191-5a (exhaust emissions?)

  1. #1
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    Default Z22YH fault code 1191-5a (exhaust emissions?)

    2004 Vectra Direct Estate Z22YH 71,000 miles

    At 54,000 miles fuel pump & regulator replaced
    At 68,000 miles fuel regulator replaced

    Car has just failed its MOT on the exhaust emissions.

    The tester rev'd the engine hard for considerable periods in order to heat it up and help with the test to no avail.

    Returned home and did a fault code check and up came P1191-52.
    Cleared the code and went for a run car went into limp mode with a code P1191-5a.

    I remember when the regulator failed at 68,000 it only completely failed when the engine was hot so I assume that the regulator has failed again.

    However,going back to the MOT test fail would a failing fuel regulator affect the emissions test?

    Thanks Dave

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    Full Member kenp's Avatar
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    yes it would probaly fail..

    but yes either regulator, sensor or pump.. have you gotted the revised parts on regulator and pump? if yes then its probaly the sensor now...

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    Thanks Kemp.

    The pump & regulator are the revised ones.

    Unfortunately My MOT has just run out so I need to try and rectify the problem quickly, so just to confirm please:-
    The sensor influences the exhaust emissions and can demonstrate that it is failing by the engine loosing power when very hot.

    Would the sensor perhaps also cause the regulator to fail?

    Can you please help me identify the sensor as the the Haynes manual (page 4A-10, Picture 14.7a) doesn't make it very clear.
    Oh and do you perhaps have a rough idea of cost?

    Many thanks Dave
    Last edited by DaveG; 30th April 2012 at 21:09.

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    Full Member kenp's Avatar
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    Yes.. as the sensor tells how much pressure there is.. but are your HP pump from continental? and not Siemens?

    but the field remedy, and a bit to check for you:

    But it is not a easy part to find out.. but is it drivable so you can pressure the car without problems (fast accelration load ect. and above circa 3000 RPM if yes probaly not the HP pump) but probaly regulator or sensor.

    General Remark:
    Low pressure failure (P1191/5A or 52) are mainly caused by high pressure pump defects, in some cases also by rail pressure sensor or regulator. High pressure failure (P1191/11 or 5B) are definitely not caused by a high pressure pump failure. It has been discovered that rail pressure valves are swelling and may stuck closed. Consequently the pressure inside the rail will increase and finally the engine stalls. If a new regulator is installed, ensure that only improved parts as of production date 226 09 (shown on down side of part, last 5 digits in 3rd. line) are usedIn case of customer complaint proceed as follows to verify the faulty

    part:1. Check fuel feed pressure at high-pressure pump with manometer (engine running) Is primary feed pressure less than 3,4 bar? Yes: Low pressure fuel feed failure -> check fuse, relay, intank module.No:

    2. Measure fuel pressure in the high pressure rail at idle by using Tech 2 Datalist. Is fuel pressure in the high pressure rail less than 600 kPa? Yes: High-pressure pump defect, replace.No:

    3. Pull off connector (two-core) of the fuel pressure regulator. Measure the voltage of the fuel pressure sensor at 3000 RPM (standing vehicle) with TECH 2. Is Voltage greater than 1,2 V?
    Yes: Fuel pressure regulator defect, replace.
    No: Defect is not clearly allocable to one component. Proceed according to TIS 2000 service instruction.

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    Thanks again Kemp.

    It is a Continental pump.
    New regulator recently fitted has following codes:-
    S-5375-04 84593
    GM 24404015
    TM 9030 040 11
    So your note indicates that the "040 11" means that it is the improved one.

    Now that the engine has cooled took it for a short (5 mile run) with hard acceleration and high revs and it ran absolutely fine with no fault codes showing.

    Will pop down to dealer tomorrow and order up fuel sensor.

    Dave

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    Full Member kenp's Avatar
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    That clealy says to me thats its NOT the HP pump.. as mine when it was the pump, was a bad/non runner all the time..

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    A quick thought - would a dirty EGR (Though showing no fault codes) adversely affect the emissions?

    Dave

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    yes it would (i think to remember) but the EGR can be disabeled at the dealers.. mine have been when i got a new inletmanifold.

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    Dealer didn't have fuel sensor (£65 +vat) in stock.

    Went for a 30 mile drive this morning and drove the car hard with no problems though yesterday's run indicates there is probably of some kind with the regulator and or sensor.

    Anyway I cleaned the throttle body and EGR valve and to my surprise the car passed the emissions test this afternoon with the following results:-

    ................. Limits......actual value
    Fast Idle test
    ......CO........<=0.300%.....0.278% (yesterday it didn't drop below 0.360%)
    ..... HC........<=200 ppm.....13 ppm
    ......lambda...0.970-1.030...1.005
    Natural Idle Test
    ......CO.......<=0.500.......0.073%

    So was it the throttle body or EGR or something that has cleared itself?

    The CO however at fast idle seems pretty close to the limits.

    Having spent a fair bit of time and money preparing it for the MOT I'm reluctant at the moment to incur any further expenditure so we'll keep the part numbers for the sensor and the regulator "on file".

    Thanks,
    Dave
    Last edited by DaveG; 1st May 2012 at 16:59.

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    Quote Originally Posted by kenp View Post
    1. Check fuel feed pressure at high-pressure pump with manometer (engine running) Is primary feed pressure less than 3,4 bar? Yes: Low pressure fuel feed failure -> check fuse, relay, intank module.No:

    2. Measure fuel pressure in the high pressure rail at idle by using Tech 2 Datalist. Is fuel pressure in the high pressure rail less than 600 kPa? Yes: High-pressure pump defect, replace.No:

    3. Pull off connector (two-core) of the fuel pressure regulator. Measure the voltage of the fuel pressure sensor at 3000 RPM (standing vehicle) with TECH 2. Is Voltage greater than 1,2 V?
    Yes: Fuel pressure regulator defect, replace.
    No: Defect is not clearly allocable to one component. Proceed according to TIS 2000 service instruction.
    Thx, this rly help me!

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