I just recently did the following:

replaced front valve block
replaced front valve block accumulator
rebuilt rear valve block
replaced rear valve block accumulator
replaced pulsation dampener
replaced return line accumulator/dampener
replaced hose that goes from front valve block to left strut
replaced hose that goes from front valve block to right strut
replaced hose that goes from pump to pulsation dampener/pressure limiting valve

here's my problem, when I start the car pressure builds to 250 bar. Pressure is supposed to be regulated to 200 bar. The high pressure in the system is causing fluid to just pour our of the pressure limiting valve. I replaced the pressure limiting valve thinking it might be the problem, but the system still remained at 250 bar and after about 10 minutes at idle the new pressure relief valve starting pouring out fluid.

The hose that goes from the pump to the pulsation dampener originally had some sort of metal inside of the first flexible rubber hose section, very similar to a power steering line that has it dampen noise as a flow restrictor. When I replaced that hose I had one built with flare nut ends and as a result it does not have the piece of metal inside of the first rubber hose.

I'm thinking either the new hose is the reason the pressure is too high and I keep blowing pressure relief valves (not sure if they are trashed now or not) or maybe the suction restrictor on the pump isn't working correctly (at some point in the past someone had replaced the pump and for some reason the wiring going to the suction restrictor on the pump was cut and then spliced back together). Anyone have any clue on this?

The pressure relief valve is leaking out of the bolt next to the pressure sensor. Originally it had what looks like a cap in it in the middle. When it started leaking this cap blew off and there is an allen wrench head underneath now showing. Do I need the cap thing back on to get the thing to stop leaking? (I have no clue where it is btw) Do I need to turn the allen wrench head at all and if so which direction and how much?

I am totally lost here and super frustrated as I have spent an enormous amount of time and money on this suspension refresh project.

 

Tough problem. I can't answer your questions about the restrictors or blow off, but with all of the lines replaced, can you be certain they are plumbed correctly? I can envision this problem if the lines to a couple ports were swapped. Let us know what resolves this issue.

 

They are plumbed correctly. I went into STAR and actuated each wheel independently and each wheel worked up/down properly.

The pressure running at 250 bar b/c of either the restrictor not being there in the new hose, the pressure limited valve not operating properly (2 not working properly is hard for me to believe), or the suction restrictor not operating correctly.

 

Just ran across your question as to ‘ too much pressure’ and fluid escaping from relief valve. I changed pump, lines, and rebuilt front and rear valve blocks an am having same issue, that is, pressure relieving through relief valve.
I am stumped an frustrated.
did you ever solve the problem and figure out the cause of pressure?
please advise, thanks

 

The return line & pressure line are swapped on the front valve block. You’ve probably ruined the pressure relief valve & will need a new one. Hopefully you didn’t also ruin the rear valve block. In my case I did. Expensive lesson. The two lines look like they should go the opposite of what they do so it’s easy to confuse them.