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