New in a Berlingo that need a new injection pump?

[swedish]

New here, live in Sweden and got a 2004 Berlingo 2,0 HDI for free. Thought it could be a nice run about for my small workshop where I mainly work on old brittish cars.
The Berlingo was for free because it will not start. Read the DTC and got one saying P1210 fuel pressure regulator open Circuit. Code comes not back after deleted until I crank the Engine. Had a look on the pump and got hold of a pump from a slightly newer car, replaced the regulator but still wont start. Very low fuel pressure when cranking, about 50 bar. Demanded pressure by the ECU is 400 bar. Blocked the return lines both from pump and rail but still very low pressure. SO I have come to the conclusion that the pump has given in. The filter is new, the tank filter is clear, tank is Clean, lines are ok but there was metal debrie in both the tank and the filter cup, guess it comes from the pump.

I have talked to people and they say there shall be a mesh filter in the inlet into the pump that use to clog up, but I find no filter there. Fuel flow freely and it is possible to pump fuel thru the pump and injectors with the hand rubber ball pump, with some resistance.

I have been warned that it is NOT possible to change the pump to a second hand one since it is coded to the immobilizer, is that true? I have asked a Peugeot workshop but they only look troubled and dont know they say, and say that they dont want to do any work on the car because it is old and probably will cost to much to repair.

To find out if there is a immobilizer problem I looked at the status of the Immo in the DTC reader and it says "ECU adapted", I hope it means that the ECU is unlocked. There is no key or security light on in the dash.

My greatest concern right now is if the pump is coded or not. Unfortunately the extra pump I got dont fit the Engine.

[cancunia]

Hi & welcome!

The 1.9d fuel pump has a fuel cut off solenoid linked to the immobiliser, but I'm not 100% sure about the 2.0. So far as I know, the 2.0 immobiliser is on the injectors only but there may another on the pump.
Sorry, can't help too much..

[frank]

perhaps only the uk spec ones had an immobiliser ? i dont see any key sign on the dash, maybe the checklight flashes if i try the wrong key ? most ecu,s can be flashed to remove it tho

[swedish]

thanks for the replies!  

There is a fuel cut of valve on the pump, that probably is linked to the Immo, but is it coded to the Immo or not meaning it can not be replaced easily that is my great million dollar question.

Contacted a Peugeot workshop today, a bit more helpful there, they promised to get back to me. next Citroen shop is some 2 hrs drive from here. Have tried phoning but only get stupid answers, have to go there myself.

[cancunia]

thanks for the replies!  

There is a fuel cut of valve on the pump, that probably is linked to the Immo, but is it coded to the Immo or not meaning it can not be replaced easily that is my great million dollar question.

Contacted a Peugeot workshop today, a bit more helpful there, they promised to get back to me. next Citroen shop is some 2 hrs drive from here. Have tried phoning but only get stupid answers, have to go there myself.

On the 1.9 motor, the fuel cut off valve is hidden behind a metal shell to stop it from being removed, you need to grind off part of the pump casing to remove it.
If the valves on the 2.0 are easy enough to remove, chances are they are not related to the immobiliser. If you can remove any component that has electrical wiring, it can probably be used on a different pump, just in case.

[swedish]

The Peugeot workshop got back to me! The pump in the Peugeot looks just like the one in the Citroen. There are two electrically operated valves on the pump, one is called fuel cut of valve and the other fuel pressure regulator. Neighter one of them has any step that involves programming when replaced in the workshop manual. It simply says unscrew and fit the new one. Both are fitted on the outside of the pump, no need for removing any covers.
There is a crashed Berlingo at the breakers yard with a 2,0 HDI, same year, will try that pump in my car. Since the car in the yard is crasched that must tell that the pump worked until the car was crashed.
Will get it out tomorrow friday and do the work saturday.

[swedish]

Fitted the pump from the crashed car. Guess what! It didnt start. I gave up and put an ad in a website, no replies in three days. Thought that I must give it another go.
Got hold of a wiring diagram and found the terminal in the ecu that should connect to the fuel pressureregulator. Started there since there is dtc on that one. No beep from the tester. Tried the other terminal in the fpr connector, no beep. Put the tester wires togeteher, BEEEP. Wtf. Found out where the other lead from the fpr went, and BEEP! Tried the other again, nothing. Had a look in the diagram, no connectors between the ECU and the fpr. Followed the wiring loom and right where it goes into a channel on the engine I found a couple of damaged wires. One was broken, three was damaged. I found both ends, put them together, connected the tester, BEEP! Success! Put everything back togeter and the engine started and ran perfect! guess if I am happy now!

Back to the yard today to get some small stuff from the crashed car, had a look at the loom and same wear on the wires on that one to! A wire with same color had shafed so the copper was in the open air getting green. Must be a common and rising problem on theese cars!



And now for a very french problem.
SRS code 111 say the passenger airbag switch of has a malfunction. It is just that the car is not equipped with a passenger airbag at all! No looms, no switch, no airbag, just a storage bin above the glove compartment. Also a code, 64 saying low voltage. Battery is ok and alternator is charging.
Anybody?

[Lighty]

Well done for finding the fault, it is a common issue,
Changing the fuel,pump is a tricky job, but you know that now.
The plastic ridged conduit is the problem with all cars these days, most issues now are broken wires hidden in the loom somewhere.

[Modmytop]

Fitted the pump from the crashed car. Guess what! It didnt start. I gave up and put an ad in a website, no replies in three days. Thought that I must give it another go.
Got hold of a wiring diagram and found the terminal in the ecu that should connect to the fuel pressureregulator. Started there since there is dtc on that one. No beep from the tester. Tried the other terminal in the fpr connector, no beep. Put the tester wires togeteher, BEEEP. Wtf. Found out where the other lead from the fpr went, and BEEP! Tried the other again, nothing. Had a look in the diagram, no connectors between the ECU and the fpr. Followed the wiring loom and right where it goes into a channel on the engine I found a couple of damaged wires. One was broken, three was damaged. I found both ends, put them together, connected the tester, BEEP! Success! Put everything back togeter and the engine started and ran perfect! guess if I am happy now!

Back to the yard today to get some small stuff from the crashed car, had a look at the loom and same wear on the wires on that one to! A wire with same color had shafed so the copper was in the open air getting green. Must be a common and rising problem on theese cars!



And now for a very french problem.
SRS code 111 say the passenger airbag switch of has a malfunction. It is just that the car is not equipped with a passenger airbag at all! No looms, no switch, no airbag, just a storage bin above the glove compartment. Also a code, 64 saying low voltage. Battery is ok and alternator is charging.
Anybody?


Congrats on getting it going. Re the airbag problem. I had a problem years ago with our 2.0HDi. Airbad light and Passenger Airbag Deactivated light. Both were lit. We do have a passenger airbag, but it wasn't deactivated. Turned out to be a broken wire between two of the computers in the car (BSI under dash and whatever the other is called in the engine bay, BSM??). Had to get Citroen diagnostic tool as age of car normal OBDII reader didn't work. Lexia diagnosed it to actual wire. https://www.berlingoforum.com/thread-4501.html

[Zweli]

My answer may be different from your everyday life.
I replaced my 1.9 engine to a same model WJY...after replacement the engine couldn't starter, i then replaced the stop solenoid with a universal one, now it starts and ruNs, and i disconnected the ECU. The van still runs.