Persistent sensor problem

The fuel pressure sensor (sited in the common rail) on my 2001 Rover 75 CDT has just failed for the seventh time since last June. On average the sensor lasts for about 4 - 5 weeks before failing again. When it fails the engine running becomes erratic, followed by cutting out, and finally by refusal to run at all. My dealership is up front in stating that they do not have the slightest idea why it is happening. The diesel engine in the 75 is BMW of course, and the common rail fuel system is Bosch. Bosch don't know why this is happening either! Nothing shows up on diagnostic test equipment - other than failure of the pressure sensor. Everything else - electrical currents, fuel pressures, etc, shows up as perfect. In an attempt to resolve the issue virtually every part of the fuel supply system has been replaced: High pressure fuel pump and combined fuel pressure regulator, secondary fuel pump, fuel filter housing, injectors, ECU (three times!), and still the sensor fails. Does anyone have the slightest idea as to why this should be happening or what might be causing it? The pressure sensor is basically a simple diaphragm switch and so my opinion is that it can only be damaged by over-pressurisation. If the pressure regulator is working ok (and has been replaced anyway) how can the common rail become over-pressurised? I am told that this time the car is going to a specialist diagnostic centre, or back to Longbridge, hopefully something should happen this time!

Kev

Reply to
Uno Hoo!
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In message , Uno Hoo! writes

You don't have much like with cars do you? (IIRC you used to own an Omega that had a long list of recurring problems). :-(

Do you have any idea how the sensor fails? Diaphragm or switch?

Reply to
Ian Edwards

and if it's going back to longbridge, are they going to at least supply you with a courtesy car in the meantime?

Reply to
dojj

You're right - I did own a very troublesome Omega prior to the 75! I'm beginning to think that I'm jinxed!

I have no idea precisely how the sensor fails. I am told, however, that there is only a tiny electrical 'signal' current that flows between the sensor and the ECU - not enough to 'burn out' the sensors electrics.

Kev

Reply to
Uno Hoo!

They did not have a courtesy car available - - but after a lengthy chat with a customer care case manager at Longbridge, they supplied me with a hire car. I'm not complaining - it's a Vectra Elite 2.2 auto. The rock-hard seats and firm joggly ride re-confirm why I like my 75 so much however!!

Kev

Reply to
Uno Hoo!

Perhaps they have a batch of dodgy sensors?

Reply to
Michael Cotton

In message , Uno Hoo! writes

I couldn't possibly comment. :-)

Two things spring to mind. Firstly, a faulty batch of sensors, unlikely if they're Bosch but possible and secondly, air in the system. If the feed to the pump isn't 'clean' microscopic air bubbles can wreak havoc. The damage looks like spark erosion of a metal surface. Did the first failure occur in the 4-5 week window after a major service where the fuel filter was replaced?

Reply to
Ian Edwards

message

No batch of faulty sensors because the problem appears to be totally unique to my car (at least in a persistent scenario). The fault first appeared in June last year - just two weeks *prior* to the first major service on my car. I asked my supplying dealer who carried out the service to also check out the poor engine running. They serviced the car but told me that they didn't have the necessary 'diesel expertise' to work on my engine. They wanted to contract the diagnosis out to an independent diesel engineer some miles away. Instead I took it to another Rover dealer who did have diesel technicians on the staff. (Perhaps I should have let it go to the independent??!!)

Kev

Reply to
Uno Hoo!

See above. MG/Rover and Bosch have not experienced a persistent problem like this before. No other diesel 75's appear to be similarly affected so a faulty batch does not appear to be the answer. I have found (via a Yahoo 75 owners forum) two other owners who have experienced failure of the pressure sensor but in both cases replacement solved the problem permanently.

Kev

Reply to
Uno Hoo!

In message , Uno Hoo! writes

Well that rules out one theory then but still leaves the possibility that they're either fitting the wrong sensor or they're nerfing up the new ones as they fit them, over-tightening perhaps?

Yes, the independent does sound the better option. Oh well, sorry I can't help. I presume you'll post the remedy to the group when Longbridge finally discovers the problem? - and Good Luck!

Reply to
Ian Edwards

The only common factor, apart from the car itself, would seem to be your dealer. Ask them to get either BMW or another dealer to replace it next time!

Reply to
Scott M

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