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this is my first post so please be gentile.a freind of mine has a 2003 master that won't start,there is no rail presure.when cranking 3.6bar.low pressure pump delivers 1.2litres per 30 seconds and there are no faults on clip.it had a new low and high pressure pump, rail and fuel filter last november to cure a swarf problem and was fine untill it died on the road last week.i'm pretty sure it's a g9u with cp1 injectioni would be grateful for any help.
 

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Hello and welcome to the forum.:)

Sounds as if the high pressure pump has gone again.:(

Is the unit still under warranty?

We have had a number of problems with the high pressure pumps on Masters and Traffics recently on the forum.:crazy:
 

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Discussion Starter #3
thanks for the welcome and quick reply.as to warranty i'm not sure the work was sorted by previous owner. do you know what low pressure should be when cranking or whether there is a regulator that could stop low getting to high pressure
 

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I don't know the exact pressure of the low side,but you should have a continous flow of diesel through the filter to the high pressure pump as soon as you switch the ignition on.I work for a Peugeot specialist and we have changed an awful lot of low pressure pumps.The first thing we always do is unclip one of the pumps either to or from the filter and flick the ignition on.If no diesel comes out,then we know its a low pressure pump fault.What can happen is the low pressure pump begins to break up sending fillings through the filter to the high pressure pump.These pumps are amazing pieces of engineering and create massive pressures,even when just cranking the engine over,but they can are easily damaged by metal fillings running through them.

I guess you know not to mess about with the high pressure pipes?.The pressure is around 1800 bar when the system is running properly,so any leaks at that pressure bring with them the possibility that if your hands or fingers are anywhere near them then the diesel can penetrate your skin!.You are then in serious trouble!!!:eek:

If you have diesel being pumped from the tank to the high pressure pump,then you have to suspect the high pressure pump again.The Peugeots do have a unit on the back of the high pressure pump to regulate pressure and these can cause problems,but as a new pump is £700+ and the regulator is £250+ from Peugeot,we usually source a second hand pump which comes with the regulator fitted to it.:)
 

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I'll leave the diesel problem solution to you but I notice you have an X19 - been looking at aquiring one recently meself!
Just missed a good looker on e-bay (too expesive in the end i reckoned). Went to view one same colous as yours last Sat but it had been "messed" with.
Just about to put a new 'post' on about our 1993 Master (2.5 diesel) - any chance you could view and then advise?
 

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Discussion Starter #7
i don't know if anybody is interested but the low pressure problem was an injector fault.injector stuck open probably by metal swarf.
 

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Excellent.Thanks for getting back to us.:)

There do seem to be a few injector faults with the 2.2......


You info will help in the future,thanks again.:)
 

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hi there heed a warning, before replacing any of the hp circuit make sure u only use a lint fre cloth, as cloth particles can and will block up the system, if there is evidence of metal particles in the filter replace it and either replace all fuel cicuit lines or blow the out with compressed air, would advise that the fuel tank is removed and sieved fuel through a stocking then inspect the inside of the tank for any particles, also would advise the replacement of the injector pipes! best of luck.
 

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Discussion Starter #10
lint free cloth,you sound like a renault technician.i have spoken to diesel specialists they say when swarf is found in the fuel you should replace everthing tank, pipework,pumps,hp rail and injectors this could write many vehicles off.
 

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hi there you could say that i am im classed as an rte, yes the info you have been given is true, but have had success with blowing out the fuel lines and draining and cleaning the fuel tank with a ladys stocking bit kinky i know but it does work very well as a strainer! it is unfortunate but as the system runs at such minimal tollerances the slightest particle of metal dust or fibre can screw things rightup.
 
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