P0193 fuel pressure sensor. FIXED

flash7210 · **Posted:** Mon Jun 22, 2015 7:32 pm

Symptoms:
Engine engine stumbles when accelerating from a dead stop. Feels like turbo lag with some black smoke.
Engine cruises just fine at a steady speed but any kind of acceleration causes a rough stumble.
Was monitoring fuel rail pressure and boost at the time using TorquePro. Both looked normal while driving.

When I got home I checked for air in fuel and bled some air out of the fuel head.
Checked for codes:
P0193 -fuel rail pressure sensor circuit high input
P0652 Low Voltage at the #1 Sensor Supply Circuit

Cleared the codes and test drove.
Same symptoms and same codes returned.

Checked the filter head again, no air.
Checked fuel pressure reading at idle, about 4600 psi.
While reving in neutral, seemed to go up and down like normal.
However, boost readings would occasionally go into vacuum while revving (I have never observed this before).
checked turbo vacuum actuator and it apprears to be functioning normally.

Checked intake hose, both CAC hoses, and turbo. All look and feel normal.

Is this really just a fuel pressure sensor problem or something else?
has anybody ever had to replace their fuel pressure sensor?

Symptoms have steadily gotten worse. Reving the engine and attempting to drive it cause stalling.

papaindigo · **Posted:** Mon Jun 22, 2015 8:27 pm

Does it do this without the code reader being attached? Lots of reports that running with a code reader attached causes weird problems.

flash7210 · **Posted:** Mon Jun 22, 2015 8:41 pm

Yes. Same symptoms without anything connected to the OBD port.

flash7210 · **Posted:** Mon Jun 22, 2015 8:56 pm

My first thought was a bad tank of fuel but had almost 200 miles on this tank before these symptoms.
Could still be a crapped up fuel filter but that doesnt explain the codes.

geordi · **Posted:** Mon Jun 22, 2015 9:22 pm

I'm not familiar with the second code, but the first one seems like the more likely suspect. There have been several people with fuel sensor issues that have been resolved by replacing the side sensor. I would just confirm that the side sensor is the one that generates that code. The end sensor is a bit more tricky, you CANNOT remove and replace that sensor to check it at all. If you remove it, it must be replaced. Apparently it has some form of a collapsible tip that crimps when first installed to the rail.

flash7210 · **Posted:** Tue Jun 23, 2015 9:31 am

Anyone know the correct part number for the fuel pressure sensor?
I've come up with 5159963aa and prices seem too high for such a sensor, about $300.
Also came up with Bosch 0281002921, which seems to fit some Cummins and Duramax engines.
Can anyone confirm this?

papaindigo · **Posted:** Tue Jun 23, 2015 10:00 am

I cannot be 100% sure but my notes based on past posts indicate
1. fuel rail pressure sensor (assuming it's the sensor on the side of the fuel rail) 515963AA or Bosch 0281002534
2. fuel rail or fuel pressure solenoid/valve (assuming it's the one on the end of the fuel rail) 5159964AA or Bosch 0281002705

flash7210 · **Posted:** Tue Jun 23, 2015 11:30 am

Thanks.
I have verified that...

papaindigo wrote:

Bosch 0281002534

... is superseded by Bosch 0281002921

papaindigo · **Posted:** Tue Jun 23, 2015 12:22 pm

So noted on my parts list. Thanks.

Mountainman · **Posted:** Tue Jun 23, 2015 12:59 pm

If it's a $300 sensor, I bet you'd be better off buying a whole rail off of ebay, or two, for about half that last time I saw one. I'd just ask the seller to take a close look that the end sensor has not been removed...

flash7210 · **Posted:** Tue Jun 23, 2015 3:19 pm

Mountainman wrote:

If it's a $300 sensor, I bet you'd be better off buying a whole rail off of ebay, or two, for about half that last time I saw one. I'd just ask the seller to take a close look that the end sensor has not been removed...

I thought about that but now that I have found the Bosch part number I can find a pressure sensor for under $200.

papaindigo · **Posted:** Tue Jun 23, 2015 3:30 pm

flash you might do a bit of cross referencing as it looks like that Bosch # is used by a host of vehicles so you might run into pricing something like the GM version of our MAP sensor that's dirt cheap.

Edit - just to clarify I know we can get a GM version of our MAP sensor (BOSCH # is 0 281 002 845 or GM PN 55206797) really cheap what I was wondering about but do not know the answer is whether or not the same situation might apply to the pressure sensor flash is looking for.

Mountainman · **Posted:** Tue Jun 23, 2015 3:39 pm

papaindigo wrote:

flash you might do a bit of cross referencing as it looks like that Bosch # is used by a host of vehicles so you might run into pricing something like the GM version of our MAP sensor that's dirt cheap.

X2, I'm pretty sure it was on Lost where I found a discussion about this, and someone had found the sensor for MUCH less, I think they went with the part for the GM :JEEPIN:

flash7210 · **Posted:** Mon Jun 29, 2015 6:09 pm

Replaced the fuel pressure sensor today and now it feels like it is in limp mode.
Acceleration is poor.
Fuel rail pressure seems to be stuck at 25600 psi.
Boost level is low but normal for slow acceleration.
Still getting a P0193 code. Even after clearing.
And now a p0190.

So did I install a bad sensor?
Was it the wrong sensor?
Or is it something else?

Also, I just discovered that the fuel pressure reading I see when using TorquePro does not come from the fuel pressure sensor. It comes from the fuel pressure regulator.
I tried with the pressure sensor unpluged and fuel pressure still showed 25600 psi and didnt drive any differently.
Basically what Im saying is, with the fuel pressure sensor plugged in it drives and behaves like its not plugged in at all.

rankom · **Posted:** Mon Jun 29, 2015 9:22 pm

looks like the engine is starving for fuel under load , before you get in electrical side , first disconnect short rubber return hose located near end of fuel rail , hook up 3/8 rubber fuel line 2ft long put in plastic water bottle , crank it ,if no fuel, pressure regulator is holding ok ,when engine starts , fuel rail press will jump high pressure regulator will open for 2-3 sec you see fuel going into bottle and regulator should close again ,that means fuel pressure regulator is ok. also do injector return flow test, assuming you did all the basics {no restriction from fuel tank to cp 3 pump )

flash7210 · **Posted:** Tue Jun 30, 2015 8:05 am

I'll see what I can do about testing flow from the return lines.

But this...

rankom wrote:

when engine starts , fuel rail press will jump high pressure

... is exactly what is happening. Except rail pressure is not dropping down to a normal level at any point after starting the engine.

Fuel supply from tank to filter to injection pump is all good to go.

Yes, it does seem like its starving for fuel but it also seems ECM induced. Which is why I say its in limp mode.

I can also try putting the old pressure sensor back in to see if limp mode goes away. It wasn't in limp mode before changing the sensor.

rankom · **Posted:** Tue Jun 30, 2015 4:35 pm

ok , re install old sensor , re re ecm harness clean ecm pins hook up battery and try again,

Mike92104 · **Posted:** Tue Jun 30, 2015 11:47 pm

I'm just guessing here, so don't put too much faith into what I say. I'm interpreting the codes to mean that the fuel pressure solenoid is not getting power, and it not able to open up to control the rail pressure. I would take a close look at it's wiring and connector to make sure the wiring is intact, and it's getting good power. I would NOT remove it until I was sure the wiring is intact. Geordi is correct that it has to be replaced if you remove it.

gmctd · **Posted:** Wed Jul 01, 2015 8:21 am

The Rail Pressure Sensor is the side-mount item
- the Rail Pressure Control Solenoid is screwed into the back end of the rail
- ECM commands RAIL PRESSURE via RAIL PRESSURE SOLENOID from sensed pressure at the RAIL PRESSURE SENSOR

FYI, I'm having same problem and have been unable to find source, as sensed and commanded RAIL PRESSURE are identical as scanned by DBIII factory scantool and AUTEL aftermarket scantool - still, P0193 and limp mode

And correct: RAIL PRESSURE SOLENOID is one-time install item - seal is by knife-edge in rail bore into softer surface of solenoid - only re-use would be to machine the flat outer edge of the solenoid, allowing screwed-in insertion to further depth

flash7210 · **Posted:** Wed Jul 01, 2015 12:39 pm

gmctd wrote:

FYI, I'm having same problem and have been unable to find source, as sensed and commanded RAIL PRESSURE are identical as scanned by DBIII factory scantool and AUTEL aftermarket scantool - still, P0193 and limp mode

Glad to know I'm not the only one trying to figure this out :wink:

The fuel pressure regulator/solenoid does not seem to be the problem.
Because if I disconnect it, the engine will not even start.

Hopefully I can spend more time working on it tonight.

P0193 fuel pressure sensor. FIXED

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