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The first successful usage in a production vehicle began in Japan by the mid-1990s. Dr. Shohei Itoh and Masahiko Miyaki of the Denso Corporation, a Japanese automotive parts manufacturer, developed the common rail fuel system for heavy duty vehicles and turned it into practical use on their ECD-U2 common-rail system mounted on the Hino Ranger truck and sold for general use in 1995.Denso claims the first commercial high pressure common rail system in 1995.

Modern common rail systems, although working on the same principle, are governed by an engine control unit which opens each injector electrically rather than mechanically. This was extensively prototyped in the 1990s with collaboration between Magneti Marelli, Centro Ricerche Fiat and Elasis. After research and development by the Fiat Group, the design was acquired by the German company Robert Bosch GmbH for completion of development and refinement for mass-production. In hindsight, the sale appeared to be a strategic error for Fiat, as the new technology proved to be highly profitable. The company had little choice but to sell Bosch a licence, as it was in a poor financial state at the time and lacked the resources to complete development on its own.In 1997 they extended its use for passenger cars. The first passenger car that used the common rail system was the 1997 model Alfa Romeo 156 2.4 JTD,and later on that same year Mercedes-Benz introduced it in their W202 model.