Is this a $1000 Problem???

[YW84U]

Today, I drove about 90KM on the freeway before pulling into the parking lot at a job site. As I pulled in, the engine completely quit - leaving me stranded in the intersection (and 90KM from home!!). I pushed it to the side and began to diagnose...

It would not start. When I turned the key on, I could hear the 'usual' sound of the fuel pump priming up. Although, this time, it didn't stop after 1-2 seconds, it just kept on going until I turned the key off. After turning the key on and off several times, the behaviour didn't change, and I figured something was afoot with the fuel pump or relay.

I ran inside of work, grabbed the first computer I could find, logged into the mesage board (which I always do anyway!), and began the hunt for information. I settled on suspecting the fuel pump relay under the power distribution box, and promptly borrowed a car to go get a new one. I popped the replacement in at the roadside, and VOILA! The X started like a charm, and the fuel pump went back to having that 1-2 second cycle before starting up!

Hours later, driving home (all happy for conquering yet another broken thing...) BOOM!. Dead. The engine began to bog, buck, and finally cut right out at full speed. It would not start, and the fuel pump would not cycle as per normal - kept going until key-off. I got friendly with my hazards, enjoyed a squished juice-box one of the kids left under a seat, and pondered how to pay for repairs AND a huge tow bill home.

After about ten minutes of having semis nearly sideswipe me parked on the shoulder, I gave it one last try - it WORKS AGAIN!!! I bailed back onto the freeway, in a valiant effort to get home. However, the truck ran like S**T, feeling as though it was getting too much fuel to run - it was bogging, poor acceleration... made it another 11KM and it cut out again. I would pull over, let it sit a few minutes, and try again - the same symptoms over and over - start, drive, runs like crap for 6-10KM, bog, then bucks and bangs, finally cutting out. Did this about 9 times until I made it to my driveway.

My MAF is clean, new o2, +4 Bosch plugs, wires, TPS, IAC, oil, filter, main computer, thermostat, battery, pos and neg cables all within the last few months.
I've searched, and figure maybe now I should suspect the EEC relay, fuel filter, FPR, temp sensor, or sunspots. I will replace all of them, but is there anything else I'm missing? Any input in this regard would be greatly appreciated!!

 

[rjc]

One guy mentioned the fuel pressure regulators often go out and are mounted on the fuel rails. Maybe it sends a signal back to the pump telling it to cycle. Maybe you overloaded the system and now it's stuck on high pressure all the time. Remove gas cap to relieve pressure from the system before working on anything. rc

 

[toad]

Im doing my FPR($117.00@Crappy Tire)next, just did O2(pita) I have similar problems but no stalling. The only other thing I can think of would be plugged CATs , but none of this explains the fuel pump not shuting off,Hmm must be the sun spots. Good luck

 

[bluescat]

Do you have a fuel pump reset? You might try that. Also, you might remove the chip and see if it clears. Is the check engine light on?

 

[YW84U]

Thanks for the replys.
I changed out the fuel filter (thank god for those little plastic tools), took a test drive, and got stranded again. Managed to limp into the local Fraud Dealer, and I'm told it is the result of a bad crank angle sensor. I'll pay the $380 and pick it up tomorrow, and hopefully only have to deal with sunspots.....

Cheers!

 

[Paul Gagnon]

I can tell you from experience that your dealerhip is probably guessing. Call them in the morning and tell them not to change the crank sensor. It is a $90 part that takes less than five minutes to change. It certainly isn't something that you should be paying $380 for. I had a similar problem with my truck. I followed the clues that the manual gave me and ended up changing the crank trigger, coil and TFI module. None of those parts were the problem. After I replaced the crank trigger and the coil and testing with another TFI module I was completely stumped so I went to the dealer. They (Marlborough Ford in Calgary) just guess that it was the TFI module and charged me $400 for diagnosis and parts. I told them that I didn't want them to jsut relace parts, I wanted them to troubleshoot it. They told me that they had and found the part faulty. Not 40 minutes later it stalled again and I returned to the dealership fuming. The dealership told me that they had not witnessed the stalling and had changed the part on spec. Let me tell you I wanted to knock some heads together!!!! The problem ended up being a faulty computer that they charged me another $400 for the parts and labour. I told them if I wasnted them to just replace teh parts without doing any troubleshooting I would have done it myself and saved the labour. They couldn't understand why I was upset. The ****ing *******s!

As you can tell I'm still a little upset about this incedent. Make sure you call your dealership and tell them not to replace any parts until they confirm that there are no faults with the computer.