Truck is a 2004 150 with the 5.4L, bought it at 54000mi currently has 101000. Put an Edge programmer in it at around 75000 and run 91 Octane with the level 3 package always. Change the oil every 3-4000 mi and run Quaker State Torque Power Synthetic. Truck was running strong on the way to work. Got in after work, was running great. Took two turns (out of the lot, down the block) and on the third it started running like crap. No engine light. Pulled up to a stop light and truck wouldn't keep itself running, had to hold brake and gas. Limped a couple blocks to the NAPA to take a look. Noticed that the rubber around my aftermarket (S&B) air intake was cracked. Thought of a vacuum leak. Went in and got duct tape to get me home, no dice. Had to get it hauled home. Asked some guys at work,one of whom worked for a dealership mechanicing, and he thought that possibly taking a corner at high speed with 1/4 tank of gas could starve that fuel pump and burn it up. He had heard of that a lot with Chevy's. I bought a pump but haven't put it in yet. Sounds like it kind of sucks. I did put a new fuel filter in though. Had a buddy from the local Chevy dealer bring out his pendant to help me with diagnostics. Finally got IAC code (not sure what the # was)but he figured that was because it wouldn't idle. Truck runs strong though 3000+ RPM. I held the throttle at 1000 RPM while he pulled coils. Said that when he pulled the coils on bank 1 (pass side) made no difference. On bank 2 (driver) every one almost killed it, leading us to believe that the entire bank 1 was not working. Misfire counter reads 0. If anybody has any information as to what this could be, anything would be appreciated. When I called the Ford dealer in town they said it could be a number of things but that the most likely would be the PCM. I loaded several programs into the truck afterward (to stock, to level 2, to stock, to level 3, back to stock), and nothing helped. Thought this might rule out the PCM but don't know.

 

I don't understand, you have an edge programmer, so why didn't you run the self test with that? I doubt it's the fuel pump. I'm always running my 04 on fumes and I have 166,000 on it (knocking on wood). I would start with running all the self tests- check for codes, KOEO and KOER- if it won't idle, you should get several codes on this. Reflashing the PCM doesn't automatically eliminate it. All the drivers for the injectors and coils are in the PCM and some of those are hardware drivers, so flashing won't fix a hardware problem.

If you've been driving for a while with leak around your boot, your KAM tables are messed up, I would reflash to your stock calibration, than disconnect the battery for 30 minutes to wipe out the memory and start fresh. Drive it for a couple days with the stock cal. You can just reflash the PCM and not clear out the KAM!

 

If this is a 2 valve engine, the IAC (Idle air control valve) is located on the upper plentum. If it gets dirty and sticks or fails completely it can cause the truck to idle very poorly and die. This is a known problem with these trucks, it gets clogged with EGR soot. The IAC is espically important when the engine is cold. It's basically the choke. My recommendation is remove the valve and clean with carb cleaner, if this doesn't cure it replace the valve. They're pretty cheap, about $40 or so and easy to R&R. Twins idea of unhooking the battery after repairing the leaking intake is probably not a bad one either.

 

It sounds like we need to know more about the truck.

If it's a 2004 Heritage model then it has an IAC. A new body 2004 with the 5.4 should be a 3v engine which doesn't have an IAC.

 

I believe it is the 3 valve version. It is not a heritage so I don't know what the dealer mech was saying about the IAC code. I will try that battery thing and see if it helps. I will also run the self-tests with the Edge. I had it loaned out to my brother so he could see if he thought it was worth it.

 

Does the wrench light come on? Sounds like a throttle body problem (which can set IAC codes even though there is no physical IAC) I have fixed a couple by taking off the TB and cleaning it real good. Good luck

 

Thank you all for your responses. To start off with, I had a bad battery and took it out to charge overnight last week so that should have reset the KAM tables which made no difference. I got the codes off of the EDGE and they are as follows:
P0113 - IAT Sensor Circuit High Input
P0351 - Ignition Coil A Primary Circuit Malfunction
P0353 - Ignition Coil C Primary Circuit Fault
P0355 - Ignition Coil E Primary/Secondary Circuit Fault
P0358 - Ignition Coil H Primary/Secondary Circuit Fault
P1000 - OBD System Readiness Test Not Complete

I thought that perhaps the coil faults we caused by our troubleshooting technique of removing the coils to see if it affected the truck so I reset the faults and the only message I can read now is the P1000. I did not know how to force an engine self-test so I couldn't really make the engine light come back on after clearing the messages. No indicator lights are on (Wrench/CEL).

 

P1000 is normal. Just means you haven't driven it enough to complete all the OBDII tests. On the edge, under the diagnostics, there should be a selection for self test. Sorry, I got rid of my Edge 2 years ago, but I remember being able to do it. Should be in the owners manual.

 

As far as the P0113 IAT sensor message, could that cause my problems? It was about 30 deg when we were troubleshooting, but every bit of 70 when my truck went down back in May. Would it be as simple as replacing the IAT/MAF?

 

Didn't see anything in the edge manual Twinsdad98. I am trying to not sound completely mechanically declined but I have no idea how to do the KOEO and KOER tests. Seems like on older vehicles you just cycled the ignition a few times and it did it but I tried that a dozen times with no luck. Naturally the Owners Guide merely "Guides" you back to the dealership. There are literally more pages on how to clean the truck than to troubleshoot it.

 

Last night I monitored the IAT and MAF while it was running and they seemed accurate. Truck said 38 deg outside, IAT said it was breathing in 36 deg. MAF was reading about 10 at 1000 RPM. Figure that we must have gotten that code while troubleshooting. Warmed the truck up to driving temp, shut off and restarted and still no CEL. Dunno what to do. If anyone could tell me how to do the KOEO and KOER tests it would be appreciated. I have done it on the EEC-IV comps before but that doesn't seem to work on this pickup. My spark advance at idle (3-500 RPM) was about 3, and 40 at 3000 RPM when the truck seems to smooth out. I don't know what that says but I am sure that someone on here does so I thought it may be important.