Changing the PGS16 diesel pump on a Y20DTH

[Kevin Marshall]

Hi,

I have a Vectra C 2005 DTI with a dead diesel pump (twin plug PGS16) engine code is y20dth

I have managed to source a complete working engine and pump, I also have the main ECU, Ignition key and Key reader from steering column from the donor car.

My question is once I swap the pump over what other parts do I need to change to get the car running, from what I have read so far all I need to do is change the key reader on the steering column and I won’t have to re-program the pump, is this correct.

Also are there any online articles covering the pump change and timing procedure? If not I can purchase a Haynes manual. I have access to the appropriate crank/cam locking tools and have plenty of mechanical experience. Just never worked on a Vectra diesel yet.

Cheers.

[Teapot]

I did one of these just a couple of weeks ago. Just swapping the pump c/w PSG16 pump control unit is not the easiest way. If the PSG16 PCU is working (can explain how to test that if pump is still on car) the easiest way is to move the PCU to the new pump (need to cut and solder/sleeve some wires). It is just bolted onto the top of the pump and and has a rather delicate ribbon cable going down into the pump to a sensor which is retained by 2 T10 screws.

[C-Owner]

Get the fault codes read from the dead pump.

P1631 code ?

Some thing official though to bear in mind. >>>>

PSG16 (Twin plug pumps)
This Bosch 44 terminal version contains a read/write 16bit flash memory in the PSG16 module.
Where the engine management maps are stored. We do not encourage any user testing on these models.
Other issues are that the headers are pump assigned which you cannot change or interchange between used pumps, spooling solenoids are the same as the PSG5 units and can be interchanged.



.

[C-Owner]

Shame you bought all that engine etc as these guys do a lifetime warranty on pumps and program your old unit so its a straight re-fit £250.00

http://www.ecutesting.com/catalogue/...edc010717.html

Check this link warning its slow, its a ealier engine but the principles the same.

http://vauxhall.workshop-manuals.com...ex.php?id=3358

[Teapot]

Get the fault codes read from the dead pump.

P1631 code ?

Some thing official though to bear in mind. >>>>

PSG16 (Twin plug pumps)
This Bosch 44 terminal version contains a read/write 16bit flash memory in the PSG16 module.
Where the engine management maps are stored. We do not encourage any user testing on these models.
Other issues are that the headers are pump assigned which you cannot change or interchange between used pumps, spooling solenoids are the same as the PSG5 units and can be interchanged.

The bloke who wrote that text is the one who taught me almost everything that I know about VP44 pumps and PSG5/16 units. Very nice helpful chap (Peter Remmington of Auto-Tec, Kings Lynn) and saved me a lot of money. (I've tested and repaired both PSG5 and PSG16 pumps).

[Kevin Marshall]

Hi guys, I would have responded sooner but was unaware I had replies, thanks for responding.

OP-COM found the following codes, I read online that the P0149 means a dead pump.


Read Info...

Identifier: 0x0410
VIN: W0L0ZCF6851068171
Hardware number:1401
Motor type: Y20DTH
Part Number:55352865
Software version number: VJAMS020_S
Hardware manufacturer number: 0470504223
Software Number: 1469946205C263_VB1
Programming Date: FFFFFFFF
Hardware key number: ÿÿÿÿÿÿÿÿÿÿ
System description: BOSCH0100
Type approval number: B02008
Variant programming: 0x00004019
Alpha code:
Hardware manufacturer system name: PSG16
ECU variant coding: 0x00007902


Total number of fault codes: 4

P0530 - A/C Pressure Sensor Circuit Low Input
(03) - Present

P0070 - Ambient Air Temperature Sensor Malfunction
(71) - Not present

P0149 - Injection Timing Control Circuit Malfunction
(5B) - Present

P0650 - <Unknown DTC>
(04) - Not present

[Kevin Marshall]

I did one of these just a couple of weeks ago. Just swapping the pump c/w PSG16 pump control unit is not the easiest way. If the PSG16 PCU is working (can explain how to test that if pump is still on car) the easiest way is to move the PCU to the new pump (need to cut and solder/sleeve some wires). It is just bolted onto the top of the pump and and has a rather delicate ribbon cable going down into the pump to a sensor which is retained by 2 T10 screws.

Hi,

Yes the pump is still on the car, and I can use a soldering iron & heat shrink so would definitly be intrested in your suggestion.

[Kevin Marshall]

Shame you bought all that engine etc as these guys do a lifetime warranty on pumps and program your old unit so its a straight re-fit £250.00

Wish I came here sooner LOL

I read elsewhere that these pumps cannot be repaired but this shows they can be, the main reason I purchased the whole engine with all the extras is because my car is an accident damadged repearable (very light damage), I don't have a pass/pin code for re-programing anything and to get that from vauxhall I need to be the registered keeper and show them the documents, I cannot get the documents till the car passes a vic check and it need to be running and able to move uunder its own power for the vic check.

So I cannot get the code to program any replacment pump.

[Teapot]

Well, not all faults are repairable, sometimes replacement is the only option, or perhaps the cheaper option. Usually the failure is one of the following:
1. Solenoids in the pump go short or open circuit. Sometimes this also causes (2). Peter can supply replacement solenoids for £70.
2. Transistor in the control unit burns out. This is repairable and I've done this on a PSG5 pump.
3. Mechanical failure in the pump 'core'. They can usually be repaired and auto-tec can do this.

The one I did a couple of weeks ago I diagnosed as mechanical failure, but control unit was fine. Luckily Peter had a good secondhand pump which had a dead control unit and he sold me this for a very reasonable price. I removed the control unit from my dead pump, fitted it to the replacement pump and then refitted everything to the car, set the timing and reassembled. It ran perfectly! The whole job took me nearly 2 days and a trip to Kings Lynn with the dead pump (the spare Peter had was a different part number but turned out to be compatible).

Correct diagnosis is the key to a cost-effective repair. If you were nearer to me I would help you with that, but alas you are not. I'll assume that you have verified fuel delivery to the pump (ideally use a hand-pump to force feed the injection pump and remove all air, etc. Fuel solenoid (between the injector pump outlet unions) can be tested in-situ, as can the control unit. Once these 3 items are ruled out, once can say with reasonable confidence that it is a mechanical failure.

The test procedure is not easy to explain in writing, perhaps we can arrange a phone call when you are ready to go through the test process and I'll try to guide you through it!

Hopefully we will find it is a mechanical fault and you can swap your PCU to the new base pump. If it turns out to be the control unit I can probably repair it for you by post.

[C-Owner]

@littleteapot

I keep a stock of the transistors if you need any

@Kevin Marshall

Its seems you have some time on your hands repairing this pump so check the bottom of the fuel filter housing for aluminium deposits (internal pump damage)
if that's all ok and theres no damage to the pump go for a module swap.