I found this from Mike Renner, maybe this may help. Or is this the same as your checking the path?
'This is an environmental computer issue that is causing the problem and possible resolution is explained below. This should be done by someone that is familiar with your computers, an IT person or the system administrator: '
Add the correct path to the Windows system variable.
Steps:
Open the Windows Control Panel and select 'System'. Click the 'Advanced' tab.
Click the 'Environmental Variables' button.
In the 'System Variables' section, select the 'Path' variable, and click the 'Edit' button.
In the 'Variable Value' field, append the following text to the current value, and click 'OK':Note: Do not overwrite the existing path in the 'Variable Value' field. If the path is accidentally deleted, press CTRL-Z to undo the deletion. ;C:\ProgramFiles\BusinessObjects\Common\3.5\Bin
At the 'Environmental Variables' window, click 'OK'.
At the 'System Properties' window, click 'OK'.
Print the report.
If the error still occurs, reboot the workstation, and try to print the report again.
Verify the changes to the Windows system Path environmental variable:
Open a command prompt.
In Windows, select Start / Run.
Type ""CMD"" (without quotes), and click 'OK'.
At the command prompt, Type ""PATH"" (without quotes), and press ENTER.
Verify that the path includes the changes made above.
If the error still occurs, perform the following:
Note: Do not perform this step if you are using another application that uses a version of the CRPE32.DLL Crystal Print Engine version 10 and 8.5 or earlier. Older Crystal Reports versions are not compatible with newer Crpe32.dll versions.
1. In Windows Explorer, go to C:\Windows\System32 (or C:\Winnt\System32).
2. Rename CRPE32.DLL.
3. Copy t