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Vauxhall Vivaro 2.0 M9R.780 2011 - Non start, code DF896 - Fixed #

Posted by Liam Hall on May 13, 2014, 8:20 pm

Year of Manufacture *: 2011
Engine Size and Code *: 2.0 M9R.780
( Optional ) ECU Type: Bosch
( Optional) Fault Codes: DF896

Hi, looking for some help on this one.
This is a very long story but the van came to me in bits, ie engine out and boxes full of bolts.

It is all back together and firing but not starting.

Injectors are all tested and ok.
Pump is known good.

I have fault code DF896, for which I cannot get a great description for other than fuel pressure.
On live data KOEO the rail pressure reads at 85000(not a typo) psi.
The van will cough every time you cycle the key but on prolonged cranking does not fire at all.
My thinking is that the ECU sees this massive pressure and shuts the injectors off. Plausible?
It makes no difference if the primer bulb is pumped or not.
Would it be fair to condemn fuel rail pressure sensor or is my live data suspect?
I'm going round in circles now so need a fresh approach or a little input.

Kind regards

Liam.

Re: Vauxhall Vivaro - - non start.

Posted by george ambelas <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3245' width='330' height='300' border=0 style='border:none;'> on May 13, 2014, 8:34 pm, in reply to "Vauxhall Vivaro - - non start. "
George Ambelas

what voltage do you get from the fuel pressure sensor when on crank?

Re: Vauxhall Vivaro - - non start.

Posted by Liam Hall <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3033' width='330' height='300' border=0 style='border:none;'> on May 13, 2014, 8:46 pm, in reply to "Re: Vauxhall Vivaro - - non start. "
Liam Hall

I get around 2.3 volts when cranking.

Liam.

Re: Vauxhall Vivaro - - non start.

Posted by george ambelas <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3245' width='330' height='300' border=0 style='border:none;'> on May 14, 2014, 8:55 pm, in reply to "Re: Vauxhall Vivaro - - non start. "
George Ambelas

that's far too high it should be under one volt and you need to think why this is so. is the sensor faulty? is the pressure regulator faulty? can you scope it?

Re: Vauxhall Vivaro - - non start.

Posted by Mark Carter <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1428' width='330' height='300' border=0 style='border:none;'> on May 15, 2014, 7:34 am, in reply to "Re: Vauxhall Vivaro - - non start. "
Mark Carter

What pressure are you seeing via live data KOEO with the sensor connected and disconnected?

Mark

Modern cars, Its all wizardry and witchcraft

Re: Vauxhall Vivaro - - non start.

Posted by Liam Hall <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3033' width='330' height='300' border=0 style='border:none;'> on May 16, 2014, 9:01 am, in reply to "Re: Vauxhall Vivaro - - non start. "

Mark, on live data the pressure value does not change when sensor connected or unplugged, but the voltage does.

KOEO plugged in 0.37v
KOEO unplugged 3.35v

On cranking this morning the volts go up to around 3v, so the rail pressure is not being controlled.

This system has a sensor in the rail and an IMV on the pump, I cant see why the pressure isnt being regulated.
The pump has been tested and function confirmed as good.
Also this is bosch EDC 16 with cp3 pump.
I'm told this is very unusual for this age however vauxhall do say its correct.

Liam.

Re: Vauxhall Vivaro - - non start.

Posted by Lee Mackintosh <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1348' width='330' height='300' border=0 style='border:none;'> on May 17, 2014, 3:55 pm, in reply to "Re: Vauxhall Vivaro - - non start. "
Lee Mackintosh

I always thought on most bosch common rail diesels 0.5v at frp sensor koeo was the normal reading and the plausibility test of the sensor circuit.

And I thought if unplugged the voltage value would match the
5v reference or near to it.

Have you tried a different scantool, I don't think any of my scantools report fuel pressure in psi. Normally bar or kpa/mpa.

Mark will correct me for sure, but would it be an idea to use a voltage regulator and vary the signal and see if the ecu live data reacts to it, if not then I reckon checking wiring from frp sensor back to ecu plug would be my suggestion.

I had nightmares with a 1.9dci that had fuel rails fitted, frp sensors, imv valve, (3 actually) injectors and I rewired the frp sensor wires but still no fix.

Apparently the fault was a poor connection at the ecu multiplug for the imv. I scoped it even at the time of fault but still couldn't condem it.

Although my van had different faults to yours it still had an over pressure fault so cut out.

Re: Vauxhall Vivaro - - non start.

Posted by Liam Hall <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3033' width='330' height='300' border=0 style='border:none;'> on May 18, 2014, 2:02 pm, in reply to "Re: Vauxhall Vivaro - - non start. "
Liam Hall

I have checked the wiring back to the ECU plug, and its all good.
I am beginning to suspect ECU?

Re: Vauxhall Vivaro - - non start.

Posted by Mark Carter <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1428' width='330' height='300' border=0 style='border:none;'> on May 19, 2014, 6:53 pm, in reply to "Re: Vauxhall Vivaro - - non start. "
Mark Carter

Liam, I'm away for three days and not back until Thursday. But if you are still stuck feel free to give me a call and I will help if I can.

Mark

Modern cars, Its all wizardry and witchcraft

Re: Vauxhall Vivaro - - non start.

Posted by Liam Hall <iframe src='https://members.boardhost.com/ukautotalk8/info/user=ukat3033' width='330' height='300' border=0 style='border:none;'> on May 21, 2014, 4:30 pm, in reply to "Re: Vauxhall Vivaro - - non start. "
Liam Hall

Thanks for the offer mark, the van is now with a guy more equipped than me, scoping etc.
I will hopefully post the fix later this week.

Fixed #

Posted by Liam Hall on June 5, 2014, 6:13 pm, in reply to "Re: Vauxhall Vivaro - - non start. "
Edited by board administrator June 10, 2014, 12:39 pm

FIXED AND GONE!!

After a lot of hours testing etc the fault was found to be that it had previously had the wrong ZME fitted.

The van had been to another 2 garages before me, so clearly its had parts thrown at it.

Led us all a merry dance, I must say.

Customer very grateful, and the promise of his return business was assured.

Thanks for everyones input, very valued.

Liam.

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