Ford Ranger/BT50 P0191 - How To Diagnose & Fix - DIY

In this video I go through a step by step guided process of diagnosing a long duration crank time (hard starting fault) with the engine management light on. Stored fault code - P0191 Fuel Rail Pressure Sensor Circuit - Range or Performance, Ford Ranger / Mazda BT50 Turbo Diesel engine
This method of testing is also comparable with fault codes P0192 P0193
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GerardBurke is a qualified motor technician who has completed modules & courses in manual handling and all aspects of workshop safety. These videos are not intended to be used by anyone who is not trained and or qualified to carry them out.
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The full vehicle details - FORD RANGER PJ 3.0L WEAT/WEC DOHC 16v Turbo Diesel Direct Inj. 4cyl 115kW 5sp Man 4dr Cab Chassis & Pickup RWD [12/06 - 03/09] 2006 2007 2008 2009
How to test a 3 wire diesel fuel rail pressure sensor. Guided instructions on how to DIY fix these faults.
#FRPSensor #Diagnostics #HowToFix

[@GerardBurkeBurkesGarage]

I hope you enjoy this one guys, Please Like, Share & Subscribe if you Haven't 👍 Correction at 1:48 I say Supply when getting a reading of 4.8v I meant to say Signal 👍👍👍

[@stembisonkuna7303]

Gerard Where is this thing called PVC located on a 2.5D WL engine?

[@tassietony1226]

I just cleaned the banjo fitting on my ranger and it fixed the surging trouble I had so pleased I watched this video thanks mate

[@codetutor6593]

Hey Gerard, you helped me fix both my EGR valve on a 2.0 diesel passat, and a wheel speed sensor. I have zero experience with cars, and the Money Lights are off and we're good to go for a few weeks now! (I do have experience with electronics though, so that helped with proper diagnosis of EGR - P0403) Thanks! I'll buy you a pint some time.

[@GerardBurkeBurkesGarage]

Thanks for taking the time to reach out and leave that comment, I love hearing feedback from videos I have posted and it genuinely means a lot 🙏❤️ Guess it your round next so 😜🍻🍺

[@warrentuckwell2032]

Just bought a bt with this code thx for the great video Gerard

[@jaketelford9632]

Awesome information mate thankyou I’m currently having issues with the fuel systems and the car not wanting to go over 2000 rpm again, I changed the fuel filter and ran perfect for a few days and now back to deloading at 2000, I’ll try the banjo bolt and test the voltages failing that I’ll go order the pressure sensor Thanks mate

[@juniorncube]

Did you come right.

[@thetazziedevil]

Hi there Gerard, I have a 07 bt50 3.0 D that needs the same part as you show in your video but they want nearly $300 for it I presume it comes with the fuel rail , I’m only wanting the sensor like you did in the video cheers mate keep up the great work

[@thetazziedevil]

I put one in made no difference it’s just the switch in the end of the rail nothing else

[@eshaamebrahim673]

Hi thanks for the video. I have a Ford Everest 3 Litre WE motor. I replaced the motor due to a bearing knock. The issue now is that it cranks but doesn't start. I had various people advice on having the ECU tested to an auto electrician telling me that there's no fuel going down into the motor. Do you have any advice on what I can do?

[@mwalsh3037]

These are my favorite type videos 🖖 Top man, great fix

[@GerardBurkeBurkesGarage]

I also love making them

[@infinitygaming9594]

hello,,you seem a very good and tidy mechanic ,great work,,,i have a mazda bt-50 that doesnt start up...only downhill with 2-3rd gear it starts,,, when i change the fuel rail pressure sensor it works for a few months then again same thing doesnt start,,can you help me or give me any advice?,,i also tested back leakage(+saw your video on that) but my car was fine

[@stevehavnar3743]

Please help ,my mazda bt50 Won't start, this happened after I remove the rail pressure sensor,,

[@LIAM7831]

Great video, just subscribed. I'm in Ireland you sound like your familiar to there :) . I have a 2.5td ranger year 2011, losing power on and off today it would hardly pull up hill then it might go again but constantly down on power over last few months. I put in new injectors and cleaned out diesel tank still has the issue. Any suggestions, thanks for the help..No lights coming up on the dash. Tks again

[@rajnigadhra3247]

Thanks mate , it fixed mine problem . once again thanks for sharing great stuff.

[@GerardBurkeBurkesGarage]

Thanks for letting me know. Delighted it helped you out Rajni and I appreciate the comment ❤️🙏

[@paulthompson1654]

Common fuel rail pressure relief valves are also a problem and will produce intermittent starts . Faulty ECU also cause this .

[@DylanRabier]

Great job. Thanks for sharing 👍

[@GerardBurkeBurkesGarage]

Thank Dylan

[@mosupithupatsogong7418]

I have the same Ford ranger and it sometimes cuts while driving on a high speed and also hard to start. I have changed the filter. What could be the problem?

[@gugussatria364]

Istimiwir wong 👍

[@Fishingandrocks]

I have a similar problem but P0193. Replaced the sensor and ok for about 2 weeks now will not start again and same code. Any tips appreciated

[@iankelly2110]

Well done Gerard nice diag.

[@GerardBurkeBurkesGarage]

Cheers Ian, thanks very much 👍

[@EliasTau]

Great advise, appreciate very much

[@will2461-j2n]

So I might have missed it but was the issue you were getting 1.9v at 2500rpm when you should have been getting 2.5v.

[@patkelly7999]

Good stuff Gerard, Thankyou:):)

[@GerardBurkeBurkesGarage]

Cheers Pat, lots more videos on the way 👍😉

[@Hawko2196]

Hey mate can a fault performance chip also throw codes like P093 and P0191

[@125sm3]

Great explanation and good practical advice.

[@GerardBurkeBurkesGarage]

Thanks very much, genuinely appreciate it 🙏👌👍

[@amorreyes-f6g]

Hi, I have ford ranger 2007, 2.5 , tdci. When i start it , it run but die immediately , it will run if i press on the diesel pedal and gradually release it until it stable in idle. I notice that the engine struggle between 1000 to 1500 rpm as if it like to stop. If i increse the rpm from idle if it pass at that rpm i can feel the engine struggle but if it pass that range of rpm it will stabilze , same happening from high rpm to idle. It also stall when i drive it especially from high speed going to idle state. Any idea what causing it. ..thanks ... i have zero knowledge in car repair....

[@jimmymorrison8151]

Hi Jimmy from jayem autore pairs I have a 2012 ford territory 3 V6 Diesel , I use G scan computer and fault code P008800 fuel rail / system pressure too high + DSC fault , traction lifts stays on and Orange triangle symbol stays on as well the car is on limp mode when driven . Any tips or suggestions, advice would be appropriate. Cheers

[@thomascouzens4558]

Legend cheers mate

[@JS-ri2rx]

Mine is showing a fault intermittently. Changed the sensor and cleared but went faulty again the same day..I cant be sure if there's an electrical fault. It could be a dodgy bksch sensor or fault in the wiring. I have been using Shell V power unleaded. Its had a recent fuel.filter fitted. But one min the sensor works then fault light again.

[@toby621]

Hi I have a 2008 ranger At high reeves the tacko jumps the dashboard shows a car with a key in it The motor runs crap cutting in and out no code cums up on code reader the ford dealer can’t work it out would you have any ideas for me I put a new radio in and it keeps needing to be reset when the car plays up

[@duanecampbell5278]

Hi Gerard. Long shot here but what would be the cause of a 2008 Ford ranger just cutting out while driving. All the dials on the dash drop down and the airbag light is coming on permanently. It does and jerks around Thanks in advance

[@TheKeenMechanic]

Great Video. Thank you

[@GerardBurkeBurkesGarage]

Thanks, it is much appreciated 👍

[@bluffrockstar]

I have a Ford Ranger 3.2 2014, I'm getting an error code "P228D - Fuel Pressure Regulator A Exceeded Control Limits - Pressure Too High". Could this possibly be the sensor? I'm assuming the sensor behaves as the regulator as well, so only other problem I can think of is the fuel pump?

[@nojeemotukoya9965]

What voltage is expected on the signal wire with good or new sensor

[@stuartwilson1890]

Do yo know the cause of the hot start issue on the 3.0 tdci ranger regards Stuart

[@BeamRider100]

I was getting this. I believe it was when I filled up at a station with water contamination. I changed the fuel filter, but still a problem. I kept purging the fuel filter once a week for about 9 months before it went away. I also threw in some Fuel Doctor in there at the end and after about 3 purges, after that, it fixed the hot start problem. (obviously draining out the tank and blowing out all the lines everywhere would have worked quicker)

[@darioandrade8484]

I have a problem in my Mazda but it's a little bit different, some times she die when I'm driving and is almost impossible to start again. Any advice?

[@calvinknox6290]

Hi guys, so ran into abit of a issue with my ford ranger 2007 4x4 2.5. So I was driving back home and the truck cut out, upon pulling it out of gear and attempting to start while on the dual carriage, started back up and soon as I went to put into gear whole truck locked up and smoke blared from everywhere, Pulled out of gear and coasted into hard shoulder, tried to start up, banging then starter locked up, got towed home as wasn't far. checked underneath and attempted to restart when home, starter locked up again after few cranks, pulled starter and checked with mirror, couldn't see any damage to inside clutch or fly, replaced starter. Attempted restart, starts up with banging sound from gearbox/back of engine area. Cuts out if you don't accerlatrate upon starting. Decided to check timing as at 96k miles, don't think last owner done it, got timing kit and lined up timing marks fine, was pretty tight at certain points of rotation to top dead centre that had me alittle worried. Replaced timing and all lines up fine. Restarted truck same banging, ripped gearbox off for inspection, no issues with new clutch fitted 3000 miles ago, fly wheel couldn't see any issues. Opened rocker cover and couldn't see any damage up there. Injectors have all been removed previously and new seals put on. I did see abit of oil leak from the top left of rocker cover head area on the back of the engine which is dripping down onto the gearbox. Also forgot to say, only diagnostic code was for air mass flow sensor, replaced it. I'm currently away kayaking till the weekend so gave myself a break from sorting my new headache, thinking next is pressure test and possible piston issue? Hopefully I'm over thinking it.. as was thinking was gearbox but couldn't find any issue with it, any way to verify gearbox? Thanks for any info or input on where to go next. sadly I didn't make a video of the truck when running

[@90albert0]

I'm trying to remove the same sensor on my Skoda diesel. How come there was no fuel coming out when your removed the sensor? My one would not turn at all, it feels jammed stuck, and the wrench would start bending/damaging the old switch. Some suggested to remove the rail and attach it to a vice grip and do it that way but it seems like a lot of work....

[@GerardBurkeBurkesGarage]

The vehicle was left idle for a long time while waiting for the part to come. As for your problem if you can't remove it in place you will most likely need go deeper and remove the rail also. If you are using poor quality spanners that could be an issue with the open end spreading under pressure causing damage (just a thought)

[@markparsons1652]

Thanks very helpful!

[@azmanjolinus9650]

Can its cause the car not going to start if that's sensor got problem??

[@bradwest7803]

Hi Gerard, I have a 2010 Ranger 3L Diesel that will only start with a short spray of SYB. When its running its perfect but soon as you shut it off and try to start no good wont start. Any ideas??

[@shiobeharry]

I have this same problem with. 2.5

[@Thabzalzk]

Same here

[@hoseamupopiwa5691]

Anyone find the solution to this issue?

[@Travis-k5g]

​@@hoseamupopiwa5691yep check the fuel rail pressure relief valve about $35 , it was the culprit on my 2008 3.0ltr bt50

[@paulreyjolitsvillar5644]

what is the code of that fuel rail pressure sensor that u replace

[@DawidWillem-np2zn]

I have bt 50 2012 model sometimes cut it self while driving high speed and pick up again

[@danilobagnas175]

How to test scv of ford ranger t6.maybe you can help me . thank you in advance

[@petejago9153]

Came across this as I'm having a nightmare trying to find out why my 2007 2.5 tdci ranger won't start when hot. spins over well and has new injectors (genuine) no fault codes. anyone any ideas.

[@JohnnysSpeedShop]

Great stuff lad....where's your aussie accent ? lol...kidding aside keep the irish one...I lost mine a while ago....😕😕

[@GerardBurkeBurkesGarage]

Thanks Johnny, be near impossible to shake my accent, plus I have a lot of Irish friends over here as well. They all sound the same 😂😂😂🔊🤣 Maybe ya might get it back 😜🤣

[@JohnnysSpeedShop]

@@GerardBurkeBurkesGarage aye I'm sure it would come back if I was back there for a few months...lol.

[@nelsonmurutsi9941]

Hi Mr Gerald I have Mazda BT 50 2.5 diesel, I'm looking for fuel pressure sensor I don't get we is mounted. Can u help pls.

[@narkrammstein]

Do we need to gasket for fuel pressure sensor?

[@jamesgonsalves6415]

Where can I buy that part online ?

[@ainsleyayliffe9055]

I am currently having troubles with the ford ranger 2007 3l tdci. The engine management light is on and it won't allow me to rev above 2250 rpm. Anyone know a fix or possible cause ?

[@cmk-vlog]

Try changing the map sensor.. mine having almost same problem.. wont rev past 2.5k rpm last time..

[@lina3445]

Where would this be on a 2017 Chevy impala a 2.5 engine 4 cylinder

[@NorwegianPatriot]

Could this also solve a p0093 fault?

[@mayowaodus6310]

Can a faulty fuel pressure sensor prevent injector pulsation on a Ford ranger 2014 2.2 diesel. Got no power at the injectors

[@stevehavnar3743]

My madzabt50 turbodiesel won't start, this happened after I had removed the rail pressure sensor,no diesel coming to the injectors at all, can anyone out there help,please

[@brodyritz4933]

What did you find out? I am having same issue. Much fuel to pump but not a drop out the high pressure side.

[@brendenoliphant9983]

My ford ranger cut out on 2500 rmp

[@kesatrianusantara1744]

Salam ARSY SEVENNINE

[@ajmalmeer8109]

My Vaicall to much parablam

[@marulephaladi745]

Hi I have a 2010 Ford everest 3.0 TDCi WEAT, engine has been rebuilt after breaking down. The engine now runs smoothly on idling but won't rev. Please help?

[@RotrexInvestments]

Hi, did you manage to resolve this? Having the same experience with the same car