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Fuel Rail Pressure Sensor Replacement
 
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Pelican Technical Article:

Fuel Rail Pressure Sensor Replacement

Nick Czerula

Time:

4 hours4 hrs

Tab:

$300

Talent:

*****

Tools:

Set of sockets (10mm, 13mm), flathead screwdriver

Applicable Models:

R56 MINI Cooper S Hatchback (2007-11)

Parts Required:

Fuel rail pressure sensor, fuel line, intake manifold gasket and related fasteners

Hot Tip:

Work with a cool engine

Performance Gain:

Remedy knock sensor fault codes

Complementary Modification:

Replace engine oil

The fuel rail pressure (FRP) sensor is mounted to the fuel rail on turbocharged engines. This sensor measures fuel rail pressure, sending the signal to the DME. . In the rail, the compressed fuel is stored temporarily and distributed to the high-pressure fuel injectors. A silicon element on a metal membrane measures the fuel delivery pressure in the rail. The measuring range of the rail-pressure sensor is from 0 to 160 bar.

If the rail-pressure sensor fails, the volume control valve is placed in emergency operation by the DME. When there is a problem in the circuit or the sensor fails the check engine light will come on. A fault code will be stored describing the current issue.

P0190, 0x2848: Fuel rail pressure circuit

P0192, 0x2849 - Fuel rail pressure circuit low

P0192, 0x2BDA - Fuel rail pressure circuit low

P0193, 0x2BD9 - Fuel rail pressure circuit short to positive

Remember that your car may have been serviced before and had parts replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you're working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Never work on your vehicle if you feel the task is beyond your ability.

Our vehicle may vary slightly from yours as models do change and evolve, as they grow older. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

Disconnect the negative (-) battery cable. See our tech article on battery connection notes.

Remove the intake manifold. See our tech article on intake manifold removing.

Before removing the sensor, the fuel rail pressure has to be relieved. You can unplug the in-tank fuel pump. Then run the engine until the vehicle stalls. This will remove the majority of the fuel rail pressure. See our tech article on fuel pump replacing for connector access.

The fuel rail pressure (FRP) sensor (red arrow) is mounted to the fuel rail on turbocharged engines.
Figure 1

The fuel rail pressure (FRP) sensor (red arrow) is mounted to the fuel rail on turbocharged engines.

The negative battery cable should already be removed, when removing the intake.
Figure 2

The negative battery cable should already be removed, when removing the intake. If it isn't, remove it now (red arrow).

The fuel line from the high pressure fuel pump to the fuel rail is shown here (red arrows).
Figure 3

The fuel line from the high pressure fuel pump to the fuel rail is shown here (red arrows). When this fuel line is loosened it has to be replaced. There are two nuts at each end. Loosen these while covering the nut with a rag to bleed off the remaining fuel rail pressure. Use a 12mm line wrench.

This photo shows the upper nut on the line being bled-off (red arrow) with a rag in place to catch any escaping fuel (inset).
Figure 4

This photo shows the upper nut on the line being bled-off (red arrow) with a rag in place to catch any escaping fuel (inset).

Working at the top of the fuel rail, cut the tie straps (red arrows) and remove the harness from the fuel rail.
Figure 5

Working at the top of the fuel rail, cut the tie straps (red arrows) and remove the harness from the fuel rail.

Working at the sensor, disconnect the electrical (red arrow) connector by lifting the tab and pulling it straight off.
Figure 6

Working at the sensor, disconnect the electrical (red arrow) connector by lifting the tab and pulling it straight off.

Working at the sensor, loosen it 1/2 a turn.
Figure 7

Working at the sensor, loosen it 1/2 a turn. The sensor hex boss is 27mm. However a 27mm wrench is too long to fit into the space. I used an adjustable wrench, as it fits better into the engine compartment.

Unscrew and remove the sensor from the fuel rail (red arrow).
Figure 8

Unscrew and remove the sensor from the fuel rail (red arrow). Then reverse these steps to install a new one. Remember to use new seals and gaskets. In addition, replace the high pressure fuel line. Clear any fault codes when complete.


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Comments and Suggestions:
Netshie Comments: Can fuel sensor on the injector rail cause a car not to start,
October 29, 2016
  Followup from the Pelican Staff: not that I know of. - Nick at Pelican Parts  
Matt Comments: Hello I have an 08'mini cooper 1.4L. I ran over a tire just the tread and it shut my car off and wont start. It has no fuel pressure.I check the relay and its ok. It's not leaking any fulid and no wires hanging down.Any help wouldbe great
October 3, 2016
  Followup from the Pelican Staff: Check the fuel pump fuse and relay. If Ok, possibly damaged to the fuel tank. I don't have the wiring for non-us models, so I can;t be more specific. - Nick at Pelican Parts  

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