Began as a no start now low fuel pressure

Tiny
MELM
  • MEMBER
  • 2003 FORD E-SERIES VAN
  • 5.4L
  • V8
  • 2WD
  • AUTOMATIC
  • 130,000 MILES
I bought this van a few months ago. It worked great. Until a few weeks ago I got in to go to town and it would turn over fine but would not start. Looked under the hood and saw no problem. Got back in and it started right up and continued to do so for several weeks. Then one day I stopped at a store (on a slight incline) and when I came out same issue. A scan showed a p-code for misfire on number 6. When it would still not start the next day had it towed to a shop. They kept it a couple of weeks and it started every time. They did have to put in a new battery. I brought it home and since it was fairly new to me I replaced the air filter, fuel filter, spark plugs, COPs, inertia switch and discovered the fuel pressure that had been between 30 and 40 psi was now down to 18 to 20 PSI. I replaced the in-tank fuel pump; still low. I replaced the fuel pressure regulator; still low. Still starts right up every time and runs fine. Baffled, I took the new AC Delco fuel filter out and put the old Motorcraft filter back in and the pressure jumped right up to 40 psi. Must have been a bad new AC Delco filter. Bought a new Wix filter and put it in and the pressure is back to 18 to 20 PSI. It still starts every time (can hear the fuel pump prime up) and seems to run fine. When you turn the key on the pressure slowly climbs to about 12 and then slowly goes up to 20 when you start the engine. With the old filter soon as you turn the key on the gauge jumps up to 40 and when you start it drops down to about 33. I put the gauge on before I took the AC Delco filter out and never moved it off the schrader valve throughout all three filters, so I know the setup was the same and the gauge is good. What is going on?
Thursday, April 22nd, 2021 AT 1:24 PM

7 Replies

Tiny
ASEMASTER6371
  • MECHANIC
  • 52,797 POSTS
Good afternoon,

I would use a Motorcraft fuel filter for the replacement. Did you try a new Motorcraft filter? Some systems are brand sensitive. 40 pounds is on the mark.

Did you cut the old ones apart and see if they were clogged with debris from the tank?

https://www.2carpros.com/articles/how-to-change-a-fuel-filter

Also, be sure the replacement filters were installed correctly. You can install them backward and this is the result.

Roy
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Thursday, April 22nd, 2021 AT 2:10 PM
Tiny
MELM
  • MEMBER
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Thanks for your quick response. None of our auto parts stores here had a new Motorcraft filter for my van but I have one on the way to be here in the morning. I did not cut the AC Delco or Wix filters open because they are brand new and each had been run lest than half an hour. I didn't want to cut the Motorcraft filter open until I knew it wouldn't be my only workable filter if I had an emergency that required me to put the van back on the road. While I had the fuel tank down and the top open, in order to change the fuel pump, (35 gallon mid-tank with about 17 gallons of fuel) I was able to rock it back and forth and it looked very clean. What would the likely outcome be if I drove it with the current filters that only offer 18 to 20 PSI?

Is there any history of this 2003 van and/or engine just not starting and then just as mysteriously the next time starting with no interaction? I guess what I am asking is although it is currently not setting any codes will I just not know I have not fixed the problem until it strands me again? The curse of an intermittent problem.
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Thursday, April 22nd, 2021 AT 5:21 PM
Tiny
ASEMASTER6371
  • MECHANIC
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At the low pressure, it would be a hard start and very low power from the lack of fuel at the rail. It would not run well at all.

No history found on this issue in any bulletins.

Roy
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Friday, April 23rd, 2021 AT 2:14 AM
Tiny
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  • MEMBER
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That is what I expected - a hard start and sluggish response on acceleration. But if I didn't have the gauge to see what the pressure was I could not tell any difference between starting and running at 20 psi or 40 PSI. Again that was without changing the gauge setup from one to the other (I have been down the road of faulty test gear being the real issue in other situations) and putting it under load driving it down the driveway (about 75 yards) and back. I just don't understand how it could even start at 0 psi. Because with the other filters it takes it about 5 or 10 seconds to go from 0 to 12 psi and that is going straight from no start to run with the key. The fuel pump prime sounds the same in both cases. It takes it about an additional 10 seconds to build all the way up to 20 PSI. It just feels like I am missing something.
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Friday, April 23rd, 2021 AT 6:52 AM
Tiny
ASEMASTER6371
  • MECHANIC
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I would get another gauge and retest.

Roy
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Friday, April 23rd, 2021 AT 9:11 AM
Tiny
MELM
  • MEMBER
  • 5 POSTS
That is what it was. I rented a pressure test kit from O'Reilly's Auto Parts and purchased a new Motorcraft fuel filter. But before replacing the Wix filter with the Motorcraft I used the rented kit to run the test. It tested just as it should, 40 PSI at key "on" and about 33 PSI on "run". So what was the difference? My test kit uses a system of quick connects, like on an air line, so you can quickly change adapters. The connection from the Schrader on the fuel line to the gauge was a 6 inch hose with the Ford Schrader fitting on one end and quick connect fitting on the other end. That was the only Ford adapter in the kit or I would have tried changing it out just to be sure it wasn't causing the missed reading. I had my suspicions but no other adapter to try. So I hoped with that setup showing good pressure for the original Motorcraft and not for the Wix or AC Delco I could count on its results. Still don't understand how that happened. The rented O'Reilly kit used a single brass Ford adapter from the Schrader to the gauge. Just to be sure I used their adapter with my kit in place of the 6 inch hose and the readings were the same. Just glad I ran the test before changing out the Wix filter. Now I have two new fuel filters on hand. Thanks again for your help.
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Wednesday, April 28th, 2021 AT 5:45 AM
Tiny
ASEMASTER6371
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You are welcome.

Roy
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Wednesday, April 28th, 2021 AT 2:05 PM

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