Hard starting?

Tiny
TANG_J
  • MEMBER
  • 1988 FORD BRONCO
  • 5.0L
  • V8
  • 4WD
  • AUTOMATIC
  • 150,000 MILES
Hello all,

I rebuilt a 302 EFI and have replaced almost everything in the engine bay to the back of the rear tank brand new.


I have to cycle the key to the on accessory 3-4 times to have it fire right up but sometimes it does very on the weather. I’ve checked the Schrader valve on the fuel rail with a fuel gauge and it reads 38-40 psi without the engine on, I read on the forums that this is adequate and within specs so I left it hooked up overnight. Coming back to it in the morning it would drop to 3-5 psi but throwing the key back to the accessory position it would shoot back up to 38-40. With the engine on it would drop a couple psi’s but nothing major.

I have been running into the issue of this problem for a while now and have noticed that this only happens when the weather is cold, low 40’s or if it sits overnight.

I’ve replaced the fuel pump in the tank, secondary pump underneath the driver seat, new fuel pressure regulator. Brand new silicone vacuum hose. New spark plugs, spark plug wires, new battery, new starter, alternator, etc. You name it I have most likely replaced it. I’m honestly at a loss of what to do now.

Any help would be greatly appreciated. Thanks in advance!
Monday, May 1st, 2023 AT 9:01 PM

18 Replies

Tiny
KEN L
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It sounds like the fuel pump is okay, it sounds like the engine coolant sensor needs to be replaced but we should run the codes to see what comes up.

This guide can help:

https://www.2carpros.com/articles/ford-lincoln-mercury-obd1-1995-and-earlier-diagnostic-trouble-code-definition-and-retrieval

This guide may help as well:

https://www.2carpros.com/articles/engine-cranks-excessively-before-starting

Here is the location of the engine coolant sensor so you can change it out if needed. Check out the images (below). Please let us know what happens.

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Tuesday, May 2nd, 2023 AT 9:36 AM
Tiny
TANG_J
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Surely it could not be this, I’ve had this replaced as well. I will try jumping the obd1 and see if I get a code.
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Tuesday, May 2nd, 2023 AT 10:13 AM
Tiny
KEN L
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Yep, that does look new, but it could be defective. I would check the codes first before replacing it. Let me know.
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Tuesday, May 2nd, 2023 AT 1:05 PM
Tiny
TANG_J
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  • 14 POSTS
I must be doing something wrong.

I made a pigtail to the tester and the check engine light just flashed twice extremely fast. I sat there for a couple minutes while it was plugged in but nothing else flashed. I disconnected the pigtail and the turned key to the on position and there was a constant check engine light which has me ruling out that my light is bad. Nevertheless, I am going to try and replace the map sensor. I doubt it would do anything, but I will report back tomorrow.

Thanks!
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Tuesday, May 2nd, 2023 AT 5:07 PM
Tiny
KEN L
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Okay let me know, it does look like you have any codes in the system.
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Wednesday, May 3rd, 2023 AT 2:05 PM
Tiny
TANG_J
  • MEMBER
  • 14 POSTS
Nothing with the MAP sensor, if anything it made it idle worst once I got it started probably because it was an aftermarket.

Any other thoughts?
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Wednesday, May 3rd, 2023 AT 5:44 PM
Tiny
KEN L
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Can you please shoot a quick video with your phone so I can see the engine trying to start? That way I can tell for sure what's going on. You can upload it here with your response. Also try to use starting fluid to see if the engine starts better. You may have a bad ECM.
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Thursday, May 4th, 2023 AT 11:32 AM
Tiny
TANG_J
  • MEMBER
  • 14 POSTS
I will get a video of this when I’m back at the shop. I did take the ECM out thinking the capacitors were bad. One was but the other two were fine. The board had some discoloration around the resistors.

I had a buddy help me out trying to trouble shoot the problem and we shot some brake cleaner in, and it started right up.
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Thursday, May 4th, 2023 AT 11:57 AM
Tiny
KEN L
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So, it either has a lean condition at startup, or you have weak fuel pressure. Even though the PCM looks okay it can still be the problem. How do the spark plugs look? Can you remove them to check the gap and the condition (color). Also, this guide may help as well:

https://www.2carpros.com/articles/engine-cranks-excessively-before-starting

Please go over this guide and report back.
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Friday, May 5th, 2023 AT 9:46 AM
Tiny
TANG_J
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Here is a video I took with a buddy.

I’m going to try and replace the ICM that is mounted on the distributor, the distributor I bought from summit was a kit, but the ratings weren’t the best. If that doesn’t work, I have another buddy that can order a new PCM from a pick n pull.

Spark plugs are still fresh, at least I think (they’ve got less than 5 hours on them). I will take a peek, they’re the Motocraft copper and I had gapped them per spec.

I’ll check out the article listed above. Thanks for the feedback!
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Friday, May 5th, 2023 AT 9:59 PM
Tiny
KEN L
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Yep, it really looks like it is starving for fuel, if it starts well on starting fluid I would revisit the fuel pump, also does it have a new fuel filter? Thanks for the video, it helps.
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Saturday, May 6th, 2023 AT 11:30 AM
Tiny
TANG_J
  • MEMBER
  • 14 POSTS
Strange. I’ve replaced both fuel pumps. In hopes that this’ll resolve my issue. I do also have a new fuel filter.

Looking at the link attached above, I can say that the battery, IAC, spark plugs, and MAP sensor would not be the problem. They’ve all been replaced with the build. I may look into the fuel pressure regulator, I had ordered this up from AutoZone, maybe I got a faulty unit?

The endless battle of working on a Ford haha.
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Saturday, May 6th, 2023 AT 7:13 PM
Tiny
KEN L
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That could be, when you say both fuel pump does this vehicle have 2 tanks? If so, I have seen the tank switching valve cause issues will low/poor fuel delivery.
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Sunday, May 7th, 2023 AT 11:26 AM
Tiny
TANG_J
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It only has one tank, one pump in the actual tank and then there’s another underneath (right around the driver seat).
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Sunday, May 7th, 2023 AT 5:23 PM
Tiny
KEN L
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It looks like there is a fuel filter in the high-pressure pump. Have you changed the filter out? Check out the images (below). Please let us know what happens.
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Monday, May 8th, 2023 AT 5:30 PM
Tiny
TANG_J
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Yes, the fuel filter has been replaced as well.

I did replace the OE injectors with some Accel brand (part #:ACC-150821). At the time I did not know that female end would not hook up to the OE wire harness so I ended up buying pigtail adapters. I cut and soldered them into the OE wiring harness. I’m wondering if there’s too much resistance in the beginning of start up? I will check there but not 100% sure this will be resolved as my problem only happens when it is “cold” out.
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Tuesday, May 9th, 2023 AT 9:35 AM
Tiny
KEN L
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That could have something to do with it or the PCM injector drivers are getting weak. You might want to try a rebuilt/used PCM.
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Wednesday, May 10th, 2023 AT 11:07 AM
Tiny
TANG_J
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I will give that a shot.

It is still bizarre that the issue is based off of ambient temperature.

Thanks for the response!
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Wednesday, May 10th, 2023 AT 6:24 PM

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