2008 1.9CdTi 120 - Fuel Pressure Issues

[tom5190]

Not too sure if this fits under Tuning or Troubleshooting, primarily it’s troubleshooting and I can’t seem to find any answers relating to my engine on here from a search.

Car is a 2008 Vectra 1.9 Z19DT.

Ive recently had a Teapot map put onto it which has highlighted an issue with my fuel pressure.

The issue is that at WOT in any gear above 2nd the car jumps into limp mode and throws the EML up just as you hit 3000rpm. Worth noting that it feels really strong right up to the point where EML/limp kicks in, and at anything other than WOT it doesn’t do it.

I’ve done a fair few Op-Com logs which seem pretty consistent in highlighting that the fuel rail pressure can’t seem to reach anything above 125Mpa. The demand runs up to 160Mpa which results in the EML flagging a P0001-75 fault code.

The car drives really well in every other scenario, I’ve got no other engine issues and no other fault codes present.

So I've done the following so far:

New OEM Fuel Filter
2x Vpower tanks
1x Cataclean bottle in each tank

Planning on pulling the LPFP from the tank at the weekend and making sure there’s no blockages there.

My questions are:

1. A few people have mentioned the fuel pumps are prone to failing. Can I fit an R80 pump to this engine? And if so can it be fit with the larger 8v belt pulley.

2. I’m assuming that the fuel rail sensor it self is a possibility too, is there any difference between the 16v and the 8v units? Or is there any better options I can go for rather than a straight swap to a standard unit?

3. Injectors - are these prone to internal leakage as in back into the return lines?

4. Any other pointers for common issues that could be causing this?

[tom5190]

ED740203-01B4-45AD-8D98-E19FDCF159FF.jpg

One of the fuel logs attached. This is 3rd gear starting at 25mph at WOT.

[rmsNoel]

Did you get this issue resolved?

[tom5190]

I did yes, well almost...I changed/did the following:Replaced fuel filter - No effectWent through 5 diesel treatments - No effectI only run it on Vpower now - No effectRemoved LPFP and cleaned pickup & filter - No effect (although it was quite bad)Replaced Fuel Rail pressure sensor - No effectReplaced Fuel Metering Solenoid - A little improvement, graphs where better but still not fixedAt this point I realised that the issue was only present when the car was up to temperature. When first started and ‘cold’ it didn’t do it and drove a lot better.Replaced HPFP - Problem fixed Although that was a working pump from another car I ‘borrowed’ so I’m waiting for another one to put on but I’m going to gear down the pump and use the 150 belt & pulley at the same time.

[tom5190]

I did yes, well almost...I changed/did the following:Replaced fuel filter - No effectWent through 5 diesel treatments - No effectI only run it on Vpower now - No effectRemoved LPFP and cleaned pickup & filter - No effect (although it was quite bad)Replaced Fuel Rail pressure sensor - No effectReplaced Fuel Metering Solenoid - A little improvement, graphs where better but still not fixedAt this point I realised that the issue was only present when the car was up to temperature. When first started and ‘cold’ it didn’t do it and drove a lot better.Replaced HPFP - Problem fixed Although that was a working pump from another car I ‘borrowed’ so I’m waiting for another one to put on but I’m going to gear down the pump and use the 150 belt & pulley at the same time.

[Ballooncement]

Hi bud I have exactly the same problem, what pump did you get? An R80?