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Fuel pressure sensors

The advent of the autonomous car has highlighted the fundamental importance of having good sensors. That being said, we have long been committed to providing effective – and reliable – sensors to our customers. So whether you are looking for engine and transmission sensors, or for comfort and safety – not to mention emissions and e-mobility – you should definitely take a look at our range.

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Fuel
pressure sensors

The fuel pressure sensor is located on the vehicle’s common rail injection system. For reference, this rail supplies fuel to the engine’s combustion chamber

Also known as the common rail pressure sensor, its role is to transmit the fuel pressure at the inlet of the fuel rail to the ECU in order to create the perfect fuel dosage for combustion and thus reduce pollution and fuel consumption.

The measured information is then directly transmitted to the ECU – which then adjusts the fuel injection according to the measurements.

This sensor is one of the most exposed technical parts of the vehicle (dirt, dust or heat), and therefore one of the most sensitive parts that will need to be replaced most often.

We offer these sensors in retail, whereas they are sold exclusively with the common rail by the manufacturers. This makes our range the ideal solution for our customers.

Technical information
Frequently asked questions
Resources
Technical information

SYMPTOMS

The following symptoms are frequently associated with a fuel pressure sensor failure:

  • Fault signal on the dashboard;
  • Difficult vehicle start up;
  • Decreased power, acceleration and fuel efficiency;
  • Poor vehicle performance;
  • Untimely stalling.

DIAGNOSIS PROCEDURE

First and foremost, you need to visually inspect the temperature sensor to determine the presence of a fault. It is therefore strongly recommended to check that the following items are in working order:

  • The sensor’s metal body (visible dents, cracks or any kind of blow that may have damaged it);
  • The associated connector (loose connections, melted, cracked or oxidised wires);
  • The wiring (not damaged or broken).

Secondly, it is also possible to test the fuel pressure sensor with a pressure gauge. When measuring, the pressure must be between:

  • For a diesel engine between 1,300 and 2,500 bar;
  • For a petrol engine between 250 and 500 bar.

If the previous tests are not conclusive, you must replace your vehicle’s fuel pressure sensor.

 

CAUSES OF FAILURE

It is possible that a fuel pressure sensor is no longer working due to:

  • Damage to the sensor and/or its connector due to excessive vehicle vibration;
  • Oxidation of the connector tabs due to the engine environment (humidity, high temperatures).

INSTALLATION INSTRUCTIONS

To ensure a quick and efficient installation, you must refer to the following instructions:

  1. Disconnect the negative terminal of the battery.
  2. Remove the plastic cover from the engine, if present. Depending on the layout of your engine, remove the air intake to access the fuel rail and sensor.
  3. Once you have located the fuel rail, look for the test port. Place a bowl under the test port and open the test port valve with a small screwdriver to depressurize the fuel rail.
  4. Disconnect the fuel pressure sensor wire set and mounting hardware and remove it from the fuel rail.
  5. Clean the fuel rail and sensor wire set before installing the new sensor.
  6. Install the new sensor onto the fuel rail, while observing the correct torque.
  7. Reconnect the wire set to the new sensor. If you have removed the air intake to gain access to the fuel rail, refit it.
  8. Replace the engine cover and reconnect the negative battery terminal.

INSTALLATION TIPS

As the fuel pressure sensor is essential to the correct operation of the engine, it is important to follow a certain number of recommendations when replacing it:

  • Apply the tightening torque recommended by the manufacturers (45 Nm), otherwise you risk breakage, damage to the injection rail or fuel leakage;
  • Remember to change the connector at the same time as the sensor, which is often the cause of the breakdown due to vehicle vibrations;
  • Always change both the sensor and its gasket at the same time.

PREVENTIVE INFORMATION

The above items are provided for information purposes only. They do not replace the advice of a qualified technician or mechanic. We strongly recommend that you consult a professional if you are unsure of what to do. Otherwise, we cannot accept responsibility for any damage to your vehicle.

Frequently asked questions
What symptoms should I look out for?

When a fuel pressure sensor fails, a fault signal will light up on the dashboard. Your vehicle will likely have difficulty starting and its performance will be directly affected (reduced power, acceleration, and fuel efficiency). Repeated stalling is also likely to occur.

How to identify the fault?

First of all, we strongly advise you to visually check the fuel pressure sensor; i.e., the metal body of the sensor (visible dents, cracks or any kind of blow that could have damaged it), the connector (visible loose connections, melted, cracked or oxidised wires) and its wiring (ensure it is not damaged or broken).

Secondly, you can test your sensor’s correct functioning with a pressure gauge. When measuring, the pressure should be between 1,300 and 2,500 bar for a diesel engine, or between 250 and 500 bar for a petrol engine.

If the above tests are not conclusive, then it would appear that you need to replace your vehicle’s fuel pressure sensor.

Why does my fuel pressure sensor need replacing?

Although automotive sensors meet very high standards, they do not last forever, and a number of their components may require replacement; for instance, the sensor can be failing due to the oxidation of its connector tabs (due to the engine environment: humidity, excessive temperatures, etc.). Vehicle vibration can also cause damage to the sensor’s connectors.

What are the installation instructions?

We recommend the following steps to replace your fuel pressure sensor as efficiently as possible and to limit possible mistakes:

  1. Disconnect the negative terminal of the battery.
  2. Remove the plastic cover from the engine, if present. Depending on the layout of your engine, remove the air intake to access the fuel rail and sensor.
  3. Once you have located the fuel rail, look for the test port. Place a bowl under the test port and open the test port valve with a small screwdriver to depressurise the fuel rail.
  4. Disconnect the fuel pressure sensor wire set and mounting hardware and remove it from the fuel rail.
  5. Clean the fuel rail and sensor wire set before installing the new sensor.
  6. Install the new sensor onto the fuel rail, while observing the correct torque.
  7. Reconnect the wire set to the new sensor. If you have removed the air intake to gain access to the fuel rail, refit it.
  8. Replace the engine cover and reconnect the negative battery terminal.
What tips should I use to extend the life of my fuel pressure sensor?

As a sensor specialist, we recommend the following to extend your fuel pressure sensor’s durability:

  • Apply the tightening torque recommended by the manufacturers (45 Nm), otherwise you risk breakage, damage to the injection rail or fuel leakage;
  • Remember to change the connector at the same time as the sensor, which is often the cause of the breakdown due to vehicle vibrations;
  • Always change both the sensor and its gasket at the same time.
Resources
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