W203 c270 cdi cutting out epc light abd p1187 code

[Kristof1989]

Brought a 2002 w203 c270 cdi with a slightly leaking pump and cutting out issue on hard accell (epc watning light and having to come to a stop to restart the car) scanned it and all sorts came up cleared them all and drove it and only code showing is p1187 - 032 rail pressure monitoring variation. Changed the pump for a recon one off 'diesel jones' they seemed to have really positive feed back and it comes with 12 month unlimited warranty. All bolted on now he car doesnt like starting and still got the same code coming up. Previous owner told me injector seals have been done recently and filter looks shiney but going to change that. Unsure why since changing the pump its a pig to start and still getting the light.... My suspiscions are an air leak somewhere. Any suggestion??

 

[m2287]

I'd get a leak off test done on the injectors... Does it start easily on easy start?

 

[mersum1es]

Are you 200% sure hoses in side of the pump are in right order? Most common fail in these...
If ok,
Is there still air bubbles visible in clear lines?
You may try to disconnect pressure sensor (front of the rail) in order to rule out faulty pressure sensor.
Then pressure regulator may be jamming (you may try gently knock it) or also 0-ring cut there.
Finally you could make injector tank line leak test during crank.
You can disconnect aux pump out line and see is diesel coming out while cranking (ready to re-connect it fast )

Was hp- pump replacement only repair job done between start - no start situation.

 

[Kristof1989]

Leak off test is my next step but previous owner said this was done and all ok but seemed a bit skeptical when i asked about it so not 100% it was done. With old leaking pump in the car i would need easy start 1st thing in the morming or if left for long period of time after that it would always start right away. Since the pump was changed it starts on easy start and will run fine, if left for longer than 10 mins it struggles like hell to start unless i use more easy start. I will check for air bubbles later when i go back to the car but pretty sure i put pipes back in the right way as double checked images online to be sure but my memory is like a gold fish at times so will check that too

 

[mersum1es]

Oh if car starts with easy start and remains running, pipes are in right order... I understood that it won't start at all... my bad.

 

[Kristof1989]

Yer just been to the car, wont start at all unless you use easy start.... Once started it runs ok just cuts out on heavy accell and i get the code. Theres no air bubbles in the pipes. The 2 pipes that go into the pump on the left hand side both move around still...... Could this be letting air into the pump? Theres no signs of any diesel leaking anywhere.

 

[Kristof1989]

Think i might if found the issue but if someone could back my theory up that would be good. The part number on the recon pump is 6110700501 when ever i search for c270 high pressure pump the number that comes up is 6120700001 so im guessing there is a difference between pumps and one has a higher pressure output than the other.... Im guessing ones for a 4 cylinder and ones for a 5?

 

[m2287]

Think i might if found the issue but if someone could back my theory up that would be good. The part number on the recon pump is 6110700501 when ever i search for c270 high pressure pump the number that comes up is 6120700001 so im guessing there is a difference between pumps and one has a higher pressure output than the other.... Im guessing ones for a 4 cylinder and ones for a 5?

Could be... My bets on an injector.

 

[Kristof1989]

After exhausting google ive found that the pump i was supplied is for a c220, 4 cylinder engine i need a different pump for my 5 cylinder engine......... Surely there is different part numbers for a different reason......? Must be something diff between the one i got supplied to the one i need...? Getting the right pump sorted so will update when it arrives and fitted.

 

[m2287]

After exhausting google ive found that the pump i was supplied is for a c220, 4 cylinder engine i need a different pump for my 5 cylinder engine......... Surely there is different part numbers for a different reason......? Must be something diff between the one i got supplied to the one i need...? Getting the right pump sorted so will update when it arrives and fitted.

Sounds like that may well be your problem then

 

[sprinter316]

Yes they have different volumes of fuel, I can test and repair pumps and injectors, we are merc specialists

 

[Kristof1989]

Where abouts are you? Still got the same issue, got a recon pump now and still does the same. Had a leak off test and let it run for 5 mins at idle and all bottles had near on the same amount which was about an inch up a small coke bottle. Going to get a new filter tomorrow but pretty sure its not this as it look new but worth a go as i dont know what the inside is like

 

[m2287]

Where abouts are you? Still got the same issue, got a recon pump now and still does the same. Had a leak off test and let it run for 5 mins at idle and all bottles had near on the same amount which was about an inch up a small coke bottle. Going to get a new filter tomorrow but pretty sure its not this as it look new but worth a go as i dont know what the inside is like

Redo the leak off test with the engine under load and see what the results are

 

[Kristof1989]

Thanks, any suggestions on how to do it, i.e what rpm to hold it at and for how long.
Many thanks

 

[boyt]

So you still got the starting issue after pump change?

Where are you located?

Have you checked the seals on the back of the rail?

 

[Kristof1989]

I wont know until tomorrow afternoon when i get in from work as then it woulf of been left almost 24hours as once its started it always starts until left but will update tomorrow afternoon. Im located on littlehampton west sussex, Bn17. When you say the seals at the back of the rail where do you mean?
Thanks

 

[Kristof1989]

Are you relating to the ones on the pressure reg?
If so i have not yet changed these. Will get them ordered up as something else to rule out

 

[boyt]

On the back of the fuel rail is the rail pressure control valve, it's held on by two e8 bolts, remove this and there's a big black o ring, a white plastic ring and a green o ring, any nicks or wear marks on these will cause issues, before you check this, tomorrow first check the clear fuel pipes for air bubbles. Should be none, as long as you been for a long run after fitting the pump, is the new pump the new pump the correct part number?
After this try starting? If it doesn't start try doing a leak off test and see if an injector has excessive leak off, I'm in poole so a bit to see in person,

 

[Kristof1989]

Just ordered a seal kit for it to eliminate this. I tool it for about a 25 mile drive after fitting the pump and checked for air bubbles in the pipes after i went to my friends (was in his a good couple hours) no bubbles started ok. The pump is 100% the right pump as gave the company i got the pump from my reg chassis number and merc and bosch part numbers which match on the pump i got supplied. If the seal kit still doesnt cure the issue i will do a leak test under load and see what the results are.

 

[boyt]

Do a leak test when it doesn't start, you can then see which injectors are causing the issue

Andy