P0192 / Unscrupulous private seller

[freddyokel]

So to my shame I've been sold a complete lemon by a private seller.
I went to buy a 207cc 1.6Hdi and it all looked good.
Scanned clear of current codes, except a P1351. Test drove perfectly for 20-30 minutes.
On the way home, after another 20 minutes of driving the screen flashes 'Depollution system faulty' and the MIL light comes on.
100yrds later the engine cuts out and will not restart.
Scanned again and we have a P0192.
Tried starting a number of times while waiting for recovery and the car start and tick over, sometimes with the P0192/depollution warning and sometimes without.
Driving the car more than 50m and we get the faults back and the engine cuts out again.
A more in depth scan of pervious codes on the car reveals that it did exactly the same thing shortly before it's last MOT a few months ago. Car has been driven around 300 miles since.
My current plan of attack is to replace the fuel filter, then remove and clean the EGR valve before checking the wiring on and replacing the fuel pressure rail sensor.

So my questions are... is this the right thing to do? And... what did they do it to make it ok to test drive for that long? I should have noticed that the battery had been disconnected as the clock was flashing.
VIN is VF3**************[VIN obfuscated, can be read by forum staff]

[GiveMeABreak]

Ok, so just to advise you that there is known issue for fault code P0192 for this engine. It concerns stalling or cutting out or difficulty in starting.

The issue concerns poor contact of the high pressure fuel sensor contact.

The solution is a harness repair and involves marking the location of the 3 wires on the fuel high pressure fuel sensor connector, and replacing with a new connector. So may be worth checking the actual pin positions and connections on this sensor connector as if they are making intermittent contact, you can see why you will be getting these stalling and starting problems.

[freddyokel]

I'd heard rumours it was a known fault. Thanks for confirming this Marc.
I've got a filter, sensor and new connector with wires on order.
I think it makes sense to remove/clean the EGR at the same time as it's the easiest way to access the end of the fuel rail.

[GiveMeABreak]

No worries, I hope this is the fix for you.

[freddyokel]

I'm really hoping it will.
There's a whole bunch of other possibilities too like the EGR valve sharing the 5 volt supply with the sensor and causing the voltage to drop if it's clogged.
But hey... horses before zebras eh?

[freddyokel]

Weirdly there are repair looms available everywhere but nowhere can I find a video or description of anyone actually doing the fix.
There's also no mention of doing the obvious (but more expensive) fix and replacing the whole sub-harness (1922G5).
Is the problem mentioned in any official service bullitin?

[freddyokel]

So, an update.
New filter, sensor and a 'loom repair' with a new connector.
P0192 is gone. Car works fine.
Unless you thrash it. And then...

P0087 : Fuel high pressure regulation
Characterisation : Pressure below reference
Status : intermittent .
Location : local
Variables associated with the fault
Engine speed : 3855 rpm
diesel presure : 1255 bar
Diesel limited pressure : 1584 bar
pump output : 32803.92 mm3/second
diesel flow regulator voltage : 3471 mV

Is this the cheapo eBay sensor (£15)? Which apparently comes with a 2 year warranty.
Time to graph demand vs actual pressure with both the old and new sensors I think...