Ecm 2505 ecm 2509

[Roy V70 850]

Hi Everyone,

Does anyone know which sensor the above codes relate to ?

The ECM 2505 code comes up every time I try to accelerate hard or up a hill. This puts the engine into limp mode.

Also trying to get home in limp mode, I had to negotiate a steep hill which shut down the engine totally with the ECM 2509 code as well.

Having read a lot of threads on this topic, I swapped the HP pump, changed the fuel filter, still no difference.

My next line of attack is to fit a new tank pump.

Has anyone any thoughts on this.

Thanks

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V70 D5 2004 163bph 160k

[37 RUBY]

Hello Roy

I think you need to diagnose why the fuel pressure drops. Replacing components based just on those two fault codes may still not cure your issue.

If you have access to Vida you will be able to monitor what pressure the LP & HP pumps are producing.

I found this thread https://www.picoauto.com/support/topic14411-10.html which is not dissimilar to your scenario with same fault codes, loads of parts thrown at it with no resolve until page 2 when a faulty injector is identified.

[Roy V70 850]

Originally Posted by 37 RUBY

Hello Roy

I think you need to diagnose why the fuel pressure drops. Replacing components based just on those two fault codes may still not cure your issue.

If you have access to Vida you will be able to monitor what pressure the LP & HP pumps are producing.

I found this thread https://www.picoauto.com/support/topic14411-10.html which is not dissimilar to your scenario with same fault codes, loads of parts thrown at it with no resolve until page 2 when a faulty injector is identified.

Thanks for you reply. I think your right, I'm clutching at straws here and looking at what's solved the problem for other people, like tank pump, HP pump, Fuel rail sensor, fuel filter etc. (I also read that thread.)

Unfortunately I don't have access to Vida. When I got the car I purchased an icarsoft reader for Volvo/Saab. I have been able to monitor the rail pressure and current to the pressure control valve live but not the low pressure from the tank pump. It's not as good a Vida, but I didn't know about it at the time.

I've been ignoring what happened in the first place which caused all this. I got the problem when pulling out of a side street which put the engine into limp mode.

There were 3 faults :- 1) fuel pressure control valve 2) fuel high pressure 3) fuel low pressure.

I found that the valve connector was faulty and replaced it with a repair kit. (This was the subject of another thread). Since then, the valve fault has never returned, but the low pressure fault occurs every time I put my foot down.

I noticed that as you as you demand more from the accelerator, the current to valve reduces, presumably to allow more fuel from the HP pump to the rail. And so the rail pressure increases. If I think about what happened initially, the valve must have fractionally gone open circuit causing the high pressure fault, hence putting max pressure demand on the rail. This would have tripped the pressure relief valve. This valve will have never been used in the cars lifetime. I wonder now whether this valve is tripping when the pressure gets to 600,000hpa (600bar) and is getting weaker all the time. There is no sensor on this valve, it's purely mechanical so I've no way of checking it.

I know I've not considered the injectors, but the car runs smoothly. I'm now inclined to install a new relief valve.

Thanks again for your input.

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V70 D5 2004 163bph 160k

[ca2n]

Hi Roy,

|| Continuing here from the other thread ||

Getting the easier things out of the way, is the problem replicated with a (near-) full tank of diesel?

I could completely be spewing out rubbish here, but with the saddle tank arrangement in our cars, with fuel moving from one side to the other, and the two sender units which average out the fuel level on the DIM, perhaps narrowing down the issue by having a good level of diesel in the tank might help?

Sorry I can't be of more help.

[Roy V70 850]

Originally Posted by ca2n

Hi Roy,

|| Continuing here from the other thread ||

Getting the easier things out of the way, is the problem replicated with a (near-) full tank of diesel?

I could completely be spewing out rubbish here, but with the saddle tank arrangement in our cars, with fuel moving from one side to the other, and the two sender units which average out the fuel level on the DIM, perhaps narrowing down the issue by having a good level of diesel in the tank might help?

Sorry I can't be of more help.

Yes I did fill up to 3/4 to check that. The problem got worse, but maybe it's been getting worse the more I drive it anyway.

The last time I drove it, I just managed to get back home, by monitoring the current to the pressure control valve and making sure it didn't drop below 850mA to trip limp mode. Previously, it tripped at 750mA. So the tripping pressure is now about 450bar.

The tank pump did seem to work ok when I changed the fuel filter, enough to prime it, by turning the ignition on and off a number of times. The car didn't have any problems starting.

This is why I'm putting my money on the fuel pressure relief valve.

In fact I've ended up buying two injection rails. (Too complicated explain why).

However, I now have a quandary :-

1) Do I replace the whole rail and trust that I can get the injection pipe unions to seal without having to renew some. But killing two birds with one stone having replaced the sensor and the relief valve in one go.

2) Do I try to just replace the relief valve knowing how much torque I have to exert to remove it. My worry here is that I might crack the block.

Anyway thanks for your advice and of course any other advice will be most welcome, before I end up doing something stupid.

[Roy V70 850]

Just for information, I did come across this utube video :-

https://m.youtube.com/watch?v=Hxpq1LfG584

[ca2n]

I noticed that you have tried with a replacement HP pump. Was the fuel pressure regulator (FPR, or sometimes referred to as the inlet metering valve, IMV) swapped as well?

[Roy V70 850]

Originally Posted by ca2n

I noticed that you have tried with a replacement HP pump. Was the fuel pressure regulator (FPR, or sometimes referred to as the inlet metering valve, IMV) swapped as well?

I bought the pump from a scrappies and the pressure regulator came attached to it, so both were swapped.

If I now replace the rail including the pressure sensor and the relief valve, there's not much else left to try, other than the injectors. As you say, its unlikely to be the tank pump.

[ca2n]

Maybe swap out just the fuel pressure sensor first instead of the whole rail? Saves those aluminium unions from being undone?

[Roy V70 850]

Everything sorted now, however not by me.

I bought an injector rail off ebay, which just happened to be on sale from Trevor Burgess (Volvo Specialist), who is just down the road from me. I went to pick it up and told him the story to which he reckoned it was more likely to be an injector rather than the sensor or the pressure release valve.

The rail I bought was a part from a Volvo they were breaking from which they had a set of working injectors. So I let them do the diagnostics which turned out to be the injector on cylinder 1. They replaced it and everything works fine once again.

Just for information:- In his experience, the 163bhp engines are more prone to injector problems and also anyone thinking of replacing the sensor and relief valve, it is easier to replace the full rail. The pipe unions almost always nip back up afterwards.