[Mik325tds]

@blowinsmoke, I'm with you on not visiting the dealer. They come across as being arrogant to me, too.
I believe the pressure sensor on the back of the rail is actually the pressure regulator.
The doc that Yozh posted earlier in this thread is actually pretty helpful on this:

[Mik325tds]

Researching the adaptions stored in the DDE it probably also makes sense to delete the following adaptions:
- mean quantitiy adaption
- Adaption fuel pump
- Adaption rail presssure regulating valve
- Adaption fuel quantity control valve

All these are available in the Rheingold tool.

[blowinsmoke]

I don't have Rheingold. I ordered a cord, but where is a good place to get software?

[9mmkungfu]

Try:

http://cartechnology.co.uk/

and

http://www.mhhauto.com

[blowinsmoke]

Wow!! Thanks very much

[Hoooper]

Is the pressure control valve electronically activated? I would think it has to be since the pressure is so widely variable.

[Mik325tds]

That's correct - the pressure regulator is electrically controlled by the DDE.

[eurojulien]

when you clear said codes do they come back right away (hard fault) or do you have to drive the car a bit? Do they all come back at the same time? also, get the battery registered for sure.

[blowinsmoke]

The faults come back after just before it dies. I can reset them with my simple scan tool but they come back the instant it dies. It seems like they all come back at once. Or at least in the same drive cycle.

[blowinsmoke]

I have not had a chance to work on it but will get to it soon.

[blowinsmoke]

So here is where I am at. I pulled the intake CBU does not look bad. I went ahead and cleaned the intake some for the fun of it. I had to pull it because I changed the rear sensor on the rail. I think they call it a pressure regulating valve. It did no good. I believe now I have a bad HPFP. Tomorrow I'm going to try holding the pressure regulator on the HPFP open to see if I can force volume to the rail as I noticed I had no good pressure after changing the sensor at the back of the rail. I'm not sure what the appropriate bleeding technique is, but I cracked the front injector line and was not impressed by the volume/pressure seeming to be present. I ordered the tool to remove the HPFP from Germany. I also have acquired a good used HPFP off a totaled car known to run well (130 bucks for HPFP seemed like a good deal although it is used)(40k mi on HPFP). I actually brought the car to the dealer at one point but the service guy talked me into (warned me into) taking it back home. He basically suggested that I try doing it because it's going to likely be cheaper than their guys trying. I'm starting to wonder now if that's true. Oh and by the way since I changed the flow valve at the back of the rail, it won't run. I tried multiple times bleeding the system.....no go.

[blowinsmoke]

I also took the plug out to access the nut on the HPFP shaft. It's tight or whatever I was turning on was tight. It seems like a bolt in the end of the shaft more than a nut on the pump shaft like I was expecting. In all the photos I've seen of that shaft, I never saw a keyway. It seems like there is possibly a chain rubbing the gear on the pump as in holding the gear on. I may take another look in there.

[richard_tricky]

I had This issue on my 530d, same faults. Pressure regulator on the back of the pump code. And also fuel rail codes.

In the end it was the hpfp. It was found it had a small hairline crack in the internal casing of the pump, this was diagnosed with an oscilloscope in a Diesel injector specialist.

As the pressure in the pump rose it bled through the crack.

I had a rebuild on the Bosch pump using a full rebuild kit and all was well on the test bench.

Refitted to the car and all was well.

Now I know it's not a 3.5d but the problems sound pretty much the same.

[blowinsmoke]

I would be happy at this point to find that my HPFP is bad. I bet I have the same issue as above. If a different pump fixes the issue, I will take my old one to a diesel pump rebuilding place to find what happened. I have found no metal anywhere in the system yet, so that would make sense too. Did your car have drivability issues as well?

[blowinsmoke]

Could anyone explain how to use the special tool to remove the pump? Or is it self explanatory? Thanks to everyone for chiming in.

[Yozh]

There was a link in a recent thread. Link to a workshop manual that you can search and see what the instructions are. Sorry I'm in my mobile.

I think it was at workshop-manuals.com

[blowinsmoke]

SOLVED!!!!!!! I finally got my HPFP removal tool from Germany. It took a couple hours, but I switched out the HPFP with the used one. I now have NO ISSUES AT ALL!!!!!! IT RUNS GREAT!!!!! AND WOW WHAT POWER!!!!!! Tomorrow I will put my JBD on and button everything back up......thanks to everyone for your help. It was a real riddle. I wasted two $200 sensors, but saved big on a good used pump($130 vs $1400). I think I'm still under 10k in the car and it is in excellent condition. I couldn't be happier!

Next, I will disassemble the old pump and search for the issue. For the record, the pump part number is: 13517804409
$1387.82 new at husker auto parts

[TorqueAddict]

Congrats figuring that out!

[Yozh]

Awesome. Congratulations. Enjoy the ride now.

[9mmkungfu]

Under $10k for a 2010 335d with 72K miles? Yeah, you did good Congrats!

[blowinsmoke]

Update: Somewhere along the way I had broken(cracked) the return line fitting at the rear injector. BMW calls it a leakage line. You can only order the whole assembly which comes with an in-line restrictor. It was around $125 from Husker for the whole thing. Anyway said new restrictor blew in half stalling my car. I think it was defective but fortunately I still had my old one which has held up fine.
So just a heads up that those things are weak/junk.

I still need to stop at the dealer and get the battery registered but it will be worth it so I can get 4 1/2 years out of my next 5 year battery too. HA

[BB_cuda]

I had forgot about your problem. Blowinsmoke, way to hang in there and stick to your guns. I don't think I have heard of one our HPFP going bad. We have had long talks about ULSD Lubricity in other threads. I'm in the camp of additives to improve this but opinions run the full range on this. I for one am glad there is a little biodiesel mixed in at my local station. Congrats to you😊