Help! Won't Start

[djmillett]

Have a rig that I bought and am trying to get on the road. Replaces the tranny and did fine for about a week then had a couple times in stalled when stopping. The first couple times it stalled and restarted but stalled again after a few minutes and wouldn't restart for about 30 minutes.

Then it stalled while going down the freeway at full speed. Thought it was the fuel pump because I didn't hear it pressurize but it's not the pump. What should I check next?

 

[wood1]

Check for codes yet?

Have a look at the how-to threads, there is one on how to diagnose a no start condition in a logical manner.

 

[djmillett]

I guess I should have pointed out that my rig is a '94. I looked at the no start thread and it is for newer Explorer but I'll look again and see if it helps.

Check for codes yet?

If you are talking about the check engine light it has not come on.

 

[Roadrunner777]

What is your fuel pressure (PSI) after it stalls?

 

[djmillett]

What is your fuel pressure (PSI) after it stalls?

I don't know. I can't get it to start at all now. I would take it to someone but can't afford to.

What I did is since I couldn't hear the pump working I swapped out the pump with an extra I had. After it started right up and the pump was running. I let it idle for several minutes then turned it off. Later in the day I decided to take a test drive and only got about 200 feet before it stalled. I have let it set a couple times now but can’t get it to start and the pump is not coming on at all.

I’m good at replacing parts and figuring out simple things but not so good at testing and finding more complicated things.

 

[wood1]

If you turn on the ignition do you hear the fuel pump run for a couple seconds then shut off?

 

[djmillett]

No.

 

[Roadrunner777]

Ok, two paths, pick either one:

1. Key on, find the fuel pressure port just forward of the coil pack. It will look like a metal tire valve. Press the inside part, like a tire valve and see if you get gas. If not, then you have fuel issues.

2. Or... go to the power distribution box under the hood and find the fuel pump relay. Ok, does your heater blower work? Yes? Then swap the blower relay and the fuel relay and see what you get.

 

[wood1]

fuel pump relay may be your problem,
http://www.explorerforum.com/forums/showthread.php?p=2171512#post2171512
http://www.explorerforum.com/forums/showthread.php?t=329182
http://www.explorerforum.com/forums/showthread.php?t=142801

 

[djmillett]

I switched out the relay and that didn't do anything then it has been this long since I could get back to it even though I need this car.

I went out to work on it and stuck the key in and the pump started so I turned the key and it started right up. After a bit I took it for a test drive and went about 3 miles and it did the same thing and cut out. No sputter or anything, just stopped. Turn the key and no pump. Checked the relay and it was warm but not hot.

I don't have a presure gauge but I need to get one and check a couple other ideas but wondered if anyone else had an idea.

 

[MrShorty]

A fuel pressure test would probably be more interesting if the pump was actually running. If the pump isn't coming on at all, I would probably start with a wiring diagram and a voltmeter and start tracing the fuel pump circuit to see where the break in the circuit is.

 

[djmillett]

So, it's up in running again. Turned out to be a loose ground wire. Now just need to figure out a tapped noice that started after being parked about 6 months.

Thanks for the help!

 

[mikesmithfl]

I've got VERY similar problem - where was the loose ground wire?

 

[djmillett]

It was very strange, to me at least, but it ended up being the negative battery cable.

 

[mikesmithfl]

That IS weird. But, I'll make sure to clean both ends of both cables, just in case.
Thanks, good luck with yours. These things can be temperamental...
<edit>
I just noticed your location is Boise, ID - that's where this particular EX came from about 12 years ago - man, it's a small world!

 

[djmillett]

WOW! long trip.

 

[mikesmithfl]

Yep, luckily it wasn't me taking it. Half the family moved to Boise after they just couldn't take it in CA any more, but they hadn't counted on the cold. So, Florida looked nice & toasty.

I double checked the grounds and +12v sources - all were doing well, so I went further and decided to check everything I could under the hood (a lot less dirt than in the frame/wheel wells).

I came up with a real OMG-HS - two bad relays. One was the fuel pump (YES!) and the other was the original one that I swapped with the fuel pump and was the heater blower motor. I had forgot completely that the blower had stopped about a week before the fuel pump quit and when I swapped what just HAD to be a good relay for the fuel pump relay, my underused troubleshooting skills just went right on down the rest of the circuit to the fuel pump. Since everything else tested OK, it MUST be the pump. Thank goodness I hadn't actually started to take the fuel tank out!

Anyway - thanks for the assist - if I hadn't been looking at the ground wire, it would have taken a LONG time before I found that there were two bad relays.