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I have been cranking for far too long, never more than 10 seconds at a time with a min break in between but I am honestly surprised that i don't need a new starter yet.
You might try replacing the CPS (camshaft position sensor). They are a known weakness on these engines. It is just above the harmonic dampener at about the 10 o'clock position. If you decide to swap this out, get one from Ford or an International dealer and not one of the big box auto parts places, as the aftermarket ones are junk. I would buy one and swap it out if it was me. They only cost about $25 or so and it doesn't hurt to have a spare anyway. Just one 10mm bolt holds it in place.
Usually when these go bad, there is no movement in the tach while cranking, but occasionally the tach will still work while cranking. Either way the engine WILL NOT RUN without this sensor in place. You will get no smoke out the tailpipe.
ok so the CEL is no longer on when cranking, and I get no codes when plugging in the reader. Is there any way to test for a bad CPS? aka any voltage readings or anything?
ok so pulled the return line again and i am still getting air bubbles, so I suppose ill keep cranking, any idea how much fuel the engine will hold, i have pumped at least a gallon out in to a bucket , and still pretty consistent bubbles, im beginning to wonder if i might be introducing air somewhere when i crank.