Mechanics

FORD 500 FUEL RAIL PROBLEM

2005 Ford 500 • 90,000 miles

Car dies while driving. Code is 191, replaced fuel pump and inertia switch as suggested in tsb. Still occurs. To restart, must shut car off, key out and it will restart. If the key is not removed, it will not restart. I have unplugged all other components in fuel system, pump driver, fuel rail pressure etc. Till car stops, but it restarts when plugged back in without turning car off or removing key - therefore it must be a different failure.
Where should I look next?
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TG70
December 10, 2012.




TSB 07-4-7

03/07/05

MIL ON WITH DTC P0191 - FUEL RAIL PRESSURE SENSOR CIRCUIT PERFORMANCE
FORD: 2005-2006 Five Hundred, Freestyle

MERCURY: 2005-2006 Montego

This article supersedes TSB 06-18-12 to update the the Service Procedure date code format.
ISSUE
Some 2005-2006 Freestyle, Five Hundred, and Montego vehicles may exhibit intermittent malfunction indicator light (MIL) on with diagnostic trouble code (DTC) P0191 for fuel rail pressure sensor circuit performance. Other DTCs and/or driveability concerns may also be present.

ACTION
Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE

If the concern is a hard fault and can be verified, perform normal diagnostics by following revised on-line Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint tests.

For Intermittent Concerns: NOTE IF CONCERN IS FOUND AT ANY POINT WHILE PERFORMING SPECIFIC CHECKS BELOW, IT IS NOT NECESSARY TO PERFORM REMAINING CHECKS/REPAIRS.

1. A possible short of the VREF signal internal to the EGR system module (ESM) may result in less than 5 volts on the VREF signal line. To check for internal ESM short, check resistance between Pin-2 (VREF) and Pin-6 (signal return) on the ESM with ESM harness disconnected. If resistance is less than 2000 ohms, replace ESM following Workshop Manual (WSM), Section 303-08.

2. Inspect main engine harness to powertrain control module (PCM) rub through on the A/C line at back right of engine compartment. Repair as necessary.

3. Inspect fuel rail pressure and temperature sensor located at top right of engine for broken or cracked vacuum port. Replace as necessary following WSM, Section 303-14.

4. Inspect inertia fuel shutoff (IFS) located in front passenger foot well for loose or disconnected wiring/connector and build date code on switch. If switch was built before November 2005 (5 L XXX) replace switch. Date code is visible without removing switch and is located near top of switch. (Figure 1)

a. Format is Year (4=2004, 5=2005, 6=2006) Month (A=Jan, B=Feb, C=Mar "I" is not used) Day (1-31) Shift (X or Y). On all vehicles, reroute inertia switch wiring behind/under carpet pad and install cable tie over connector. (Figure 1)

5. If vehicle is built before 8/16/2006, review Freeze Frame Data for fuel level indication (FLI) and fuel rail pressure (FRP). If FLI was 25% or less and FRP reading was below 20 PSI, concern may be due to jet pump performance under high demand. Replace fuel pump module, which contains integral jet pump, following WSM, Section 310-01.

Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT : Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

OPERATION DESCRIPTION TIME

070407A 2005-2006 Freestyle, Five 0.9 Hr.
Hundred, Montego: Check
Diagnostic Trouble Codes
And Replace Exhaust Gas
Recirculation System
Module (Do Not Use With
12650D, 12650D12,
12650D30, 9756A, 9350E)

070407B 2005-2006 Freestyle, Five 0.5 Hr.
Hundred, Montego: Check
Diagnostic Trouble Codes
And Replace The Fuel Rail
Pressure And Temperature
Sensor (Do Not Use With
12650D, 12650D12,
12650D30, 9756A, 9350E)

070407C 2005-2006 Freestyle, Five 0.5 Hr.
Hundred, Montego: Check
Diagnostic Trouble Codes
And Replace The Inertia
Fuel Shutoff (IFS) Switch
(Do Not Use With 12650D,
12650D12, 12650D30,
9756A, 9350E)

070407D 2005-2006 Freestyle: 1.5 Hrs.
Check Diagnostic Trouble
Codes And Replace The
Fuel Pump, Includes Time
To Remove And Install
The Fuel Tank (Do Not
Use With 12650D,
12650D12, 12650D30,
9756A, 9350E)

070407E 2005-2006 Five Hundred, 1.3 Hrs.
Montego: Check Diagnostic
Trouble Codes And
Replace The Fuel Pump,
Includes Time To Remove
And Install The Fuel Tank
(Do Not Use With 12650D,
12650D12, 12650D30,
9756A, 9350E)

MT070407 Claim Additional Labor Actual
Time Required As Actual Time
Time Or Use SLTS
Operation If Available

DEALER CODING
CONDITION
BASIC PART NO. CODE
9H307 42

Disclaimer

this needs to be followed. Nowhere here did it say to replace pump.

It is a fuel pressure switch issue on the rail but needs to be confirmed with testing, not throwing parts at it.

Look at the flow chart also

Roy
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ASEMaster6371
Dec 10, 2012.
Roy, thanks. The attached is the process that I followed. Step 4 - The inertia switch was pre date code so I did not think it was an issue, but followed the bulletin.
Step 5 - may have been my misinterpretation and fedback fro other sites. The fuel pump was replaced because I used my obd meter and watched the pressure drop before stopping. I did not put an actual pressure gage on because there is no port.

Next I am going to monitor the pump driver to verify I have voltage signals in and out to the pump. Failure is so random it is tough to capture.

My further diagnostics may not be valid but I caused
the car to stop by disconnecting each component - pump, fuel rail pressure, egr, etc one at a time, then reconnected. But in each case I could start the car without having to turn to the off position before it could restart. In the driving failure, the car must be turned off completely before it will restart.


Tiny
TG70
Dec 12, 2012.

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