Van will not start reg CK09ENH
2009 Citroen Berlingo 1.6hdi

Hi,

I would appreciate some help, regarding the following…….

I have a van that now won’t start. There was an intermittent fault where the van stopped and wouldn’t start, but would restart after a while. It ran fine at other times.
I had the van to a garage who struggled to diagnose the exact problem, however suggested it needed a new fuel pump and new injectors.
Due to the potential high expense the van has been off the road for a while with the battery disconnected.
To date I have fitted a new high pressure pump, new timing belt/water pump, new fuel filter and starter motor, however the van will not start.
The van will start with easy start but will not run as it seems no fuel is getting to the injectors. I have fault code 05ff unexpected re-initialisation fault coming from bsi.
I have checked all fuses under the bonnet and under the dash. I have carried out a bsi reset procedure, however still no luck.
The van did run before the garage started the investigation, where several parts were removed to test things, but has not ran since. I am not even convinced it needed a new high pressure fuel pump, however I won’t know till I get it running.
I would be grateful if you can offer some advice before I throw more money at the van?

Regards……..David

Problem added: Nov 13, 2021 (3 weeks ago)
Citroen Berlingo (2009)
1.6hdi
Problem Category
Electrics, ECU, Warnings & Lights
Replies and fixes
Surprised they did not check or replace crank sensor / wiring
Thanks for your reply and I believe they did say the crank sensor was ok, but either way would this not throw up a fault when I run a diagnostic check?
I have borrowed a launch scan device which is only picking up the bsi fault, however it may have limited success with the van not starting?
I have read some comments that say only a lexia device can correctly diagnose Citroen faults?
Lexia and Diagbox are far superior for diagnosing your Citroen .If crank sensor o.k , you usually see the rev counter move slightly when cranking .
Replying to post by whittingehame:
Lexia and Diagbox are far superior for diagnosing your Citroen .If crank sensor o.k , you usually see the rev counter move slightly when cranking .
Thanks for the information. I will give that a try and see if the Rev counter moves.
I will also look into the Lexia diagnostic option.
Replying to post by David Longstaff:
Thanks for the information. I will give that a try and see if the Rev counter moves.
I will also look into the Lexia diagnostic option.
I have checked the crank issue and can confirm the Rev counter moves when cranking the engine.
Fuel pressure measured reads 1074bar (which seems ridiculously high) however when I cracked open an injector pipe, there was no fuel reaching the rail, so not sure how the rail pressure is measured?
The cranking speed was 224rpm and I read that this should be 450, however it sounds like it is cranking fast enough.
Another issue regarding the bsi fault message. After doing the bsi reset it appears to work and windows open etc, however after cranking again, the message returns.
On most common rail diesels it must reach 10,000kpa or 100bar or 1450psi of fuel pressure in the common rail for the injectors to be activated and for the engine to start. Your crank speed is low . You should never crack open an injector pipe on a common rail.
Replying to post by whittingehame:
On most common rail diesels it must reach 10,000kpa or 100bar or 1450psi of fuel pressure in the common rail for the injectors to be activated and for the engine to start. Your crank speed is low . You should never crack open an injector pipe on a common rail.
Not sure if I explained that correctly, when I said cracked open, I mean loosened the 10mm nut on one rail pipe to see if any fuel came out.
I have tested the battery with a voltage meter and it appeared to be ok, however it could be faulty if not cranking fast enough?
Do you think there could be a problem with the fuel rail pressure sensor which could explain the high reading from my diagnostic check?
It’s clear you know your stuff, but I am no mechanic and just trying to work through potential problems, so am grateful of any guidance you feel appropriate.
Replying to post by David Longstaff:
Not sure if I explained that correctly, when I said cracked open, I mean loosened the 10mm nut on one rail pipe to see if any fuel came out.
I have tested the battery with a voltage meter and it appeared to be ok, however it could be faulty if not cranking fast enough?
Do you think there could be a problem with the fuel rail pressure sensor which could explain the high reading from my diagnostic check?
It’s clear you know your stuff, but I am no mechanic and just trying to work through potential problems, so am grateful of any guidance you feel appropriate.
Forgot to mention I have also towed the van in an attempt to bump start it, however it never even attempted to start, which would back up my theory that it isn’t getting fuel, just don’t know why
You sure you are not getting your bar pressure mixed up with your psi ? What was your battery voltage as the cranking speed is half . Did you try to prime fuel filter ?
The code reader definitely said the bar pressure was 1450,, but considering your comments, 1450 psi would seem more appropriate.
When I last checked the battery voltage it was 13.6volts fully charged, however I can’t remember what it was when cranking. Now I think about it the battery does seem to drop charge quick after only turning the van over a few times.
When we tried towing the van, this was following forum comments saying that following an interruption to the fuel supply it would improve the starting potential and reduce the need to endlessly crank the engine over.
The fuel filter has been primed many times using the prime bulb and is full of fuel
A car 12 volt battery , tested from cold or overnight should not read 13.6 v unless there is something wrong with it , far too high .
Replying to post by whittingehame:
A car 12 volt battery , tested from cold or overnight should not read 13.6 v unless there is something wrong with it , far too high .
It’s a yuassa battery and currently on charge in the garage. I’ve just took the charger off and it reads 13.6 volts.
I must admit I thought it was only a problem if the voltage was lower than 12.6 and never seen any reference to a problem if higher, so what could cause it to be high?
On the battery there is a view eye which according to the image key, says it’s ok. Just noticed the battery was fitted in 2017, so not that old.
I have a multimeter and will test it tomorrow when cranking the van.
Replying to post by David Longstaff:
It’s a yuassa battery and currently on charge in the garage. I’ve just took the charger off and it reads 13.6 volts.
I must admit I thought it was only a problem if the voltage was lower than 12.6 and never seen any reference to a problem if higher, so what could cause it to be high?
On the battery there is a view eye which according to the image key, says it’s ok. Just noticed the battery was fitted in 2017, so not that old.
I have a multimeter and will test it tomorrow when cranking the van.
I tested the battery again and fully charged it was reading 12.6 when cranking and never fell below 11.6 even when losing charge, so whilst it may not be 100%, I don’t think that is the problem. Even with a poorly battery the van would have bump started and it was towed for a mile and never attempted to start once.
For some reason i do not think it is getting fuel, so why would you get good rail pressure if no fuel was entering the engine?
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