P0191 on Ford
Fuel Rail Pressure Sensor Circuit Range/Performance
P0191 on Ford vehicles indicates fuel rail pressure sensor circuit range/performance. Au7o has documented this code across 2 Ford models — most commonly on F-150, F-250 Super Duty. This code sets when the fuel rail pressure sensor's signal is out of its expected range or doesn't match what the computer expects for current conditions. On direct-injection and many modern engines, this sensor reports fuel pressure in the rail so the computer can precisely control fueling and the fuel pump. When the reading is implausible — too steady, erratic, or inconsistent with commanded pressure — this code is set, sometimes with hard starting, hesitation, or reduced power. It generally points to the sensor or its wiring, though an actual fuel-pressure problem can also trigger it. Typical repair costs on Ford range from $150 to $15,000, depending on the specific model and root cause.
Common Causes of P0191
- •Faulty fuel rail pressure sensor
- •Corroded, loose, or damaged sensor connector
- •Open, shorted, or high-resistance sensor wiring
- •Actual fuel pressure out of range (weak pump or regulator)
- •Restricted fuel filter or supply line
- •Loss of reference voltage or ground from the ECM/PCM
- •Faulty fuel pressure regulator or control valve
P0191 on Ford by Model
Ford F-150(1 issue)
- Fuel Pump Driver Module (FPDM) Corrosion and No-Start / Stalling2004-2009
2004-2009 Ford F-150 (11th-generation) suffers from Fuel Pump Driver Module (FPDM) corrosion. The aluminum-housed module mounts directly to a steel frame crossmember above the spare tire — the dissimilar-metal contact creates galvanic corrosion, accelerated by road salt and moisture. The aluminum case cracks, water shorts the internal circuit board, and the module stops driving the fuel pump. Symptoms: crank-no-start (most common), stalling after hitting a bump or stopping at lights, intermittent loss of power. Ford issued a recall for 2005-2006 F-150 FPDMs specifically; 2004 and 2007-2009 are not recall-covered but suffer the same defect. Owners typically pay $150-$400 for module replacement plus relocation hardware that mounts the module away from the steel frame.
Ford F-250 Super Duty(1 issue)
- 6.7L Power Stroke CP4 High-Pressure Fuel Pump Failure - Catastrophic Fuel System Contamination2011-2016
The 2011-2016 6.7L Power Stroke uses a Bosch CP4.2 high-pressure fuel injection pump that is fundamentally incompatible with North American diesel fuel specifications. US diesel fuel has lower lubricity than European fuel, and the CP4 pump relies on fuel for internal lubrication. Over time, the CP4 pump's internal metal components grind and generate metal shavings that are distributed throughout the entire high-pressure fuel system at 30,000+ PSI. Metal contamination destroys all downstream injectors, fuel rails, and low-pressure system components. A class action lawsuit filed against Ford alleges the company knew the CP4 was incompatible with US fuel. Catastrophic failure can occur as early as 80,000-120,000 miles and requires complete fuel system replacement costing $8,000-$15,000.
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View P0191 across all makes →Frequently Asked Questions
What does P0191 mean on Ford?▼
P0191 stands for "Fuel Rail Pressure Sensor Circuit Range/Performance." This code sets when the fuel rail pressure sensor's signal is out of its expected range or doesn't match what the computer expects for current conditions. On direct-injection and many modern engines, this sensor reports fuel pressure in the rail so the computer can precisely control fueling and the fuel pump. When the reading is implausible — too steady, erratic, or inconsistent with commanded pressure — this code is set, sometimes with hard starting, hesitation, or reduced power. It generally points to the sensor or its wiring, though an actual fuel-pressure problem can also trigger it. On Ford specifically, this code is documented across 2 models.
What causes P0191 on Ford vehicles?▼
Common causes on Ford: Faulty fuel rail pressure sensor, Corroded, loose, or damaged sensor connector, Open, shorted, or high-resistance sensor wiring, Actual fuel pressure out of range (weak pump or regulator), Restricted fuel filter or supply line. Specific causes vary by model and year — see the per-model sections below.
How much does it cost to fix P0191 on a Ford?▼
Repair costs on Ford range from $150 to $15,000, depending on the specific model and root cause.
Which Ford models have P0191 documented?▼
Au7o has documented P0191 on 2 Ford models: F-150, F-250 Super Duty.