A bit more troubleshooting on my rig leads me to believe that my P0192 code is right on the money, and my FPS has failed. I measure 24k between 1-3, but 3M between 1-2 and open between 2-3. I think it must have been on its way out when I measured it first last week.

Anybody have a great source? It is apparently used on Cummins 5.9L and some Duramax engines, too. Cheapest way seems to be to look for Cummins part #3949988, rather than for Bosch 0281002921.

I have no idea why this failed: it was fine when I removed the rail to replace the head. I didn't drop the rail or anything. Unplugging and plugging it in were the only unusual things that happened to it.

_________________
George Reiswig
2005 Jeep Liberty CRD
Suncoast, SEGR, lift, InMotion tune, homebrew B100
At 138k, new head & gasket, timing belt, rockers and swearing vocabulary

Cheapest I found in my brief search:

http://www.amazon.com/Bosch-0281002921- ... B004SRI1GG

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2005 Liberty CRD Limited
DIY Garage Remanufactured Engine with GDE Full Torque Eco Tune from mile zero.
ARP Studs
Cummins Lift Pump
Transgo HD2 Reprogramming Kit
DIY Rebuilt Tranny Pump
Suncoast Torque Converter
2nd Generation Fuel Head
Sears P1 Battery
Hot Diesel Solutions Thermostat

I wonder if there's a seal, gasket, or valve that dries out.

_________________
2005 Liberty CRD Limited
DIY Garage Remanufactured Engine with GDE Full Torque Eco Tune from mile zero.
ARP Studs
Cummins Lift Pump
Transgo HD2 Reprogramming Kit
DIY Rebuilt Tranny Pump
Suncoast Torque Converter
2nd Generation Fuel Head
Sears P1 Battery
Hot Diesel Solutions Thermostat

Rest assured I will see if I can see what failed when I pull it off.

_________________
George Reiswig
2005 Jeep Liberty CRD
Suncoast, SEGR, lift, InMotion tune, homebrew B100
At 138k, new head & gasket, timing belt, rockers and swearing vocabulary

The STANDARD FPS-16 box comes with the BOSCH part inside - Liberty Diesel fuel pressure sensor.....................................

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'05 CRD Limited
Pricol EGT, Boost
GDE Hot '11; EDGE Trail switched
SEGR; Provent; Magnaflow;
Suncoast T\C, Transgo Tow'n'Go switch;
Cummins LP module, Fleetguard filter, Filterminder
2.5" Daystar f, OME r; Ranchos; K80767's, Al's lifted uppers
Rubicons, 2.55 Goodyears
Four in a row really makes it go

As usual, there is nothing particularly clear here. But I thought I'd post what I have learned for others' "benefit."

There seem to be several different Bosch part numbers at least loosely associated with our FPS.

On my rail, it is Bosch part #0281002534. This is still available, but has been superseded by 921. I can't help but wonder if it was superseded because others besides me had mysterious sensor failures when the rail was removed from the engine.

As you start to look at applications, you find that the 534 part number was used at one point by the Cummins 5.9L and the Duramax 6.6L engines. For the Cummins engine, you now find that the part listed is available with an 851 suffix. Some places also list that for the Duramax. Others list still another part number. Prices vary greatly, including for the same part number but according to which application you use. Generally speaking, the Duramax Bosch part comes up being cheaper, but is not guaranteed to be the 921 part or the 534, either of which should work for sure.

One other person on LOST reported that they found a part with a 706 suffix, installed it, and it "ran great." Don't know for how long, but... All of these list as 1800 bar sensors, have the right terminations and supply voltages. I don't know how they vary from one another.

Then there is an Airtex part, supposedly made in the U.S. by Airtex, listed for use on our engine and sold by Rock Auto. Their part number is 5S7054, and is the least expensive option, and comes with a 12mo/12kMile warranty. (EDIT: this is the part I ordered, and it is actually the Bosch 534 part. No sealant was needed, and no fuel leaked from the rail when removed.)

I have no idea whether a sealant of any kind is recommended for the threads. At 20+kPSI, it sure seems like a good idea.

That's what I know.

_________________
George Reiswig
2005 Jeep Liberty CRD
Suncoast, SEGR, lift, InMotion tune, homebrew B100
At 138k, new head & gasket, timing belt, rockers and swearing vocabulary

I've made no effort to back-probe my new FPS replacement, suspecting that it consists of active circuitry rather than a simple resistive strain-gage element - so far I've seen nothing to indicate procedure for resistive testing the FPS module

Still can't figger out why scantool indicates measured 5900psi rail pressure when ECM is demanding 5900psi - measured always equals demand at any rpm, which should not return P019X DTC - will have to jump on it one day soonest, because it's starting to bug me

_________________
'05 CRD Limited
Pricol EGT, Boost
GDE Hot '11; EDGE Trail switched
SEGR; Provent; Magnaflow;
Suncoast T\C, Transgo Tow'n'Go switch;
Cummins LP module, Fleetguard filter, Filterminder
2.5" Daystar f, OME r; Ranchos; K80767's, Al's lifted uppers
Rubicons, 2.55 Goodyears
Four in a row really makes it go

Gmctd,

I agree that it is probably not very worthwhile to test it with an ohmmeter.

I reached a tech at Bosch regarding the sealant, and they said to follow Jeep's recommendation. So. Llama urine it is.

_________________
George Reiswig
2005 Jeep Liberty CRD
Suncoast, SEGR, lift, InMotion tune, homebrew B100
At 138k, new head & gasket, timing belt, rockers and swearing vocabulary

You can also go on the Duramax CRD and Cummins CRD sites to see if any is using a sealant - I suspect none, as what sealant can seal 20k^psi - parts screen shows no copper ring - clean the threads and torque the module to spec - compressing the machined surface at the bottom of the bore is the seal

_________________
'05 CRD Limited
Pricol EGT, Boost
GDE Hot '11; EDGE Trail switched
SEGR; Provent; Magnaflow;
Suncoast T\C, Transgo Tow'n'Go switch;
Cummins LP module, Fleetguard filter, Filterminder
2.5" Daystar f, OME r; Ranchos; K80767's, Al's lifted uppers
Rubicons, 2.55 Goodyears
Four in a row really makes it go