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120d E82 2008 - Error 4560 Fuel Rail [SOLVED]

78K views 40 replies 10 participants last post by  Decy_bee  
#1 ·
So having a lovely drive today and just gliding down the hill and the amber engine light came on (not seen that one before) then at the bottom of the hill the engine stalled, pulled over wouldnt start, 3hrs later got towed home.

Read the fault codes
4560 Raildruck-Plausibilität mengengeregelt
4570 Raildruck-Plausibilität mengengeregelt
4610 Raildruck-Plausibilität druckgeregelt
4CAE AbgasrĂĽckfĂĽhrsteller Positionssensor, Signal

4560 is fuel rail pressure, I have under 1/4 of a tank, Now reading on the net I found a BMW 320d has a in-tank fuel pump does the 120d also ?
Then I read someone just filling the tank helped by getting it started, and changing just the filter fixed the issue!!

Anyone else seen/heard this or can help advice?

I've Ordered a filter and have to wait to get some more fuel as nearest fuel station is 4 miles away.. :( (get walking shoes on)
 
#4 ·
AP1 said:
Your new codes are no 1 glow plug and a fault with the dpf system.
Those 2 codes where from 1000 miles ago also, didn't appear on break down, just come back if I clear them ?

trying to start it I got,
4B90 RaildruckĂĽberwachung bei Motorstart

Ive logged INPA in and used the Fuel EKP to start the fuel pump and I can hear It, I get this ??
Image
 
#8 ·
  • 4B90 4B90 RaildruckĂĽberwachung bei Motorstart
    Error counter: 5 Logistic counter: 40
    1. Umweltsatz Mileage 251680 km
    2. Motordrehzahl 259.50 rpm
    3. KĂĽhlmitteltemperatur (Sensorwert vor der Korrektur) 18.07 degC
    4. maximaler Raildruck der letzten 10ms (1 Byte) 117.87 bar
    5. Einspritzmenge - Sollwert ohne Mengenausgleichsregelung (1 Byte) 36.50 mg/hub
    6. Luftmasse pro Zylinder (1 Byte) 382.92 mg/hub
    7. Luftdruck vor Einlassventil (1 Byte) 1020.08 hPa
    8. Erfasste Batteriespannung (1 Byte) 10200.93 mV
    9. Umgebungsdruck (1 Byte) 1002.38 hPa
    10. aktueller Motorstatus 8.00 -
    11. Kraftstofftemperatur (1 Byte) 18.07 degC
    12. Kraftstoffvorförderdruck - gefiltert (1 Byte) 188.32 hPa
    13. Vorfördermenge (1 Byte) 179.37 l/h
    14. Raildruck - Sollwert 404.08 bar
    15. Status - Raildruckregelmodus 0.00 -
    16. Raildruckregelung-Status des Zustandsautomaten 0.00 -
    17. Mengenregelventil - Sollwert des Ansteuerstromes (1 Byte) 996.30 mA
    18. Mengenregelventil - gefilterter Stromistwert der Stromregelung (1 Byte) 988.45 mA
    19. Raildruckregelventil-Sollstrom (1 Byte) 823.71 mA
    20. Raildruckregelventil-Stromsollwert von der Raildruckregelung (1 Byte) 831.56 mA
    21. Raildruckregelventil-Zustand der Stellwertsteuerung 0.00 -
    22. Raildruckregelventil-Adaptionsfaktor fĂĽr die Kennlinie (1 Byte) 0.91 -
    23. Raildruckregelventil-Drucksollwert von der Raildruckregelung (2 Byte) 731.17 bar
    24. Mengenregelventil - Volumenstromsollwert der Raildruckregelung (2 Byte) 100.01 mm3/s
    25. Mengenregelventil - Zustand der Stellwertsteuerung 0.00 -

Side note, really need an english INPA but tried all sorts and errors are still German, plus do the Units look correct ? Number 4. 117 bar ???? would that be psi ?
 
#14 ·
marco_polo said:
So it turns over, but doesn't fire?
Yea turns over nicely just wont fire

marco_polo said:
LPFP priming? Definitely got fuel at the injectors (no airlocks)?
Now that's the thing I wanted to do next but unsure how without breaking anything, already snapped a breather pipe that was brittle!

Whats the best way thing to check next, I have a haynes manual do I just remove an injector ?
How do I prime the LPFP and remove/check air locks ?

I did think when the fuel filter arrives I can check the fuel is getting to there.
 
#15 ·
Just as an aside really, I once had a Porsche 924S that just wouldn't start and the pump would turn itself off suggesting it had achieved required pressure into the fuel rail. After checking most things, I removed a blanking screw from the end of the fuel rail and forced the pump on (must have bypassed the pressure sensor I recall) and a dead wasp was spat out of the fuel rail into the pipe/jar I had put in place. Restored blanking screw and car started and ran perfectly. In your case there would surely be a filter to stop that soft of thing getting in the fuel.
 
#16 ·
Fuel Filter still not arrived :(

How do I check I have fuel at the injectors ?

As Haynes stated to bleed fuel system, I took return pipe off the rail and activated EKP fuel pump and fuel came out of the pipe is this good ? Im waiting for hand vacuum pump to arrive too.

Anything else would stop it from firing ?
 
#18 ·
poiuytre111 said:
Just as an aside really, I once had a Porsche 924S that just wouldn't start and the pump would turn itself off suggesting it had achieved required pressure into the fuel rail. After checking most things, I removed a blanking screw from the end of the fuel rail and forced the pump on (must have bypassed the pressure sensor I recall) and a dead wasp was spat out of the fuel rail into the pipe/jar I had put in place. Restored blanking screw and car started and ran perfectly. In your case there would surely be a filter to stop that soft of thing getting in the fuel.
The other time I had a non-starting M47 320d it was because the ECU didn't see the required rail pressure traced to a couple of injectors which were leaking too much - in that case the car would bump start but not start on the key. Changed injectors, car started. A quick Google Translate suggests that RaildruckĂĽberwachung bei Motorstart means Rail pressure monitoring at engine start... Will yours bump start ?
 
#19 ·
poiuytre111: It wouldn't bump as it stalled doing 40 down hill, though could be blocked fuel rail, I've no experience on this but read below.

Update: Fuel filter and hand vacuum pump arrived to day, So I followed the Haynes manual which states how to bleed the engine if the self priming/venting doesnt work, after filter change turn ignition on and leave it for 1 min before trying to start the engine this will start the pump and vent the fuel system, if it stalls repeat until air is out of the system. It didn't after 30 times this week :(

It then it says if the N47 engine still wont start remove the return pipe at the end of the fuel rail (towards the back of the engine next to the cam sensor connector) and place a hand vacuum pump on the rail and draw the diesel through until no air is in the system. I did this but I couldnt suck any fuel through with the hand pump (same pump they pictured too) so I assume it should flow easy!!??? does this means its blocked somewhere? I put so much pressure on it the rubber tube was collapsing?????????

So I thought filter blocked, I removed the fuel filter and replaced it, fuel poured out of here!!! But still I cant suck fuel through the return nipple on the fuel rail :(

Before I get it towed to the garage anything else I could try ?
I did read on another forum someone had the same 4B90 error fuel rail, and the out come was they removed the inlet manifold put it back and it worked.... :?

:?
 
#20 ·
update:

Well after spending ÂŁ400 on possible fixes with local garage I sent the car to the specialists who have just given me the bad news :cry:

The hpfp (high pressure fuel pump) went and now needs complete fuel system flush, new pump, new injectors, filter etc... cost over ÂŁ3000!!!!!!

The garage asked me if I had put the wrong fuel which could have caused it (which there is no way), They said they haven't done that many.. I also read a forum post of a simialr situation where the car was under BMW warranty and they said "bad fuel" ??!?!?!

The car has done 156,000 miles, has anyone else had this happen is it likely to happen again with "bad fuel"... common fault?

The car is my pride and joy... sorry was my pride and joy its the throne in my side. BMW == :cry:
 
#22 ·
devilpoweredmark said:
If you not put in wrong fuel why would all that need replacing.
Apparently when the pump goes all the swarf from it goes up stream into injectors and then tank, tank pump, fuel lines.

devilpoweredmark said:
Ps iv got a hpfp and rail. And you get a lift pump on ebay for say 50quid.
They looked and managed to find a hpfp on the shelf very lucky!!.. BMW want ÂŁ1000, the lift pump and tank should be able to be cleaned out plus down stream from the fuel filter I've got another rail although I cant see why the original cant be cleaned out anyways if you remove the reg and sensor, So that just leaves the injectors they said they may have a used set they'll check. :cry:

Is this common, considering its done 156,000, I don't want it to happen again ?
 
#24 ·
jason@bwchiptune said:
Just change the hpfp and clean the rest I've done a good few of them hpfp and not had a problem after
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Apparently the injectors need to be changed too, Hopefully they arrive today. The rest has been cleaned out.

I'm just worried about it happening again, Whats the reason for the cause... age?
 
#26 ·
poiuytre111 said:
Diesel fuel has lubricating properties which is needed by components such as the HPFP. This is why you had several questions about fuel - if you had petrol in the tank - no lubrication, not good for the pump.
Its never had petrol in, but how would one tell its "bad fuel" to quote BMW ?

The tank was low when it happened, it said 38 miles left on it and we were going down hill... could air get in ?