2007 Ford E150, 4.6L Engine, 97000 miles

At my wits end with this truck - experiencing random/intermittent stalls and forced engine shutdowns. No real pattern on when it occurs, sometimes it does it's thing on first startup, other times not. The truck runs smooth as silk when it's NOT stalling. When it does stall/stumble, I turn the key off & start back up - sometimes it returns to normal right away, sometimes it takes 3 or 4 cycles of key on off cycles. I have a decent scan tool, the Ford service manuals AND the PC/ED troubleshooting manual.

I have replaced a ton of parts through this process (to no avail so far) which I don't mind so much because they're mostly all parts I would be replacing soon anyway (I purchased this vehicle used a few months ago). Seems to be fuel delivery related, but could just as easily be electrical or data communication related. Here's the list of items replaced so far - Spark Plugs, Coil Packs, Air & Fuel Filters, PCM (Engine Computer), EGR Valve, MAF, All 4 O2 Sensors, Alternator, Serpentine Belt, Pulley & Tensioner Assembly, Fuel Pump. I'm sure this is going to be something completely ridiculous and simple - if and when it's ever resolved! I'm sure that one of the first questions to be asked will be what DTCs have come up. One that is interesting and has come up more than once is P0600, which seems to be related to communication issues. This is what caused me to replace the PCM, again to no avail.

Interesting to observe the live data when the condition occurs, is that all of the values freeze while the engine is still running and before it eventually quits on it's own. Any insight or guidance on this nightmare would be more than appreciated!

 

Check and see if it's not the fuel pump relay or the PCM relay going bad. Also check all grounds, and battery voltage.

 

Gotta agree that maybe the relays are suspect. & they are simple & not very expensive to replace....to help rule it out.

The only other thing that maybe happening is that the connections on the underside of the fuse block maybe "iffy". Might just need to be reseated or a power supply connection to the PMC or fuel pump maybe corroded or not making good contact during "certain conditions"??

Being a 07' is there a fuel pump driver module (FPM) that might have cracked or corroded. I'm not sure on the vans but it might be located near the rear axle?

 

For how long does the engine continue to run once the freeze-up is observed?

 

Have checked/swapped relays, checked main grounds (but not the large S172 splice located deep within the harness - makes me wonder because that splice has 8 legs that happen to feed DLC, MAF, 4 to PCM, 2 to BJB - fuel pump relay & PCM power relay). I am wondering about battery voltage which is right around 12.1 - it is approaching 5 years old according to the tags. Tried a new FPDM, made no difference so I kept the old one.

Yesterday I double checked the CKP by monitoring the engine rpm, and the value did NOT freeze when the engine started dying, so I will have to revisit the live data freezing issue. It usually does take a bit for the engine to die if the throttle is not disturbed, however sometimes it just dies immediately.

Thank you all for your response.

 

12.1 volts on a battery is extremely poor if the engine is off. If that's the voltage while running, your alternator isn't working. Try recharging the battery before proceeding. Low battery voltage, especially if combined with a failing alternator, can cause some really wired symptoms when the supply voltage droops below the minimum required for stable operation.

 

I do realize the 12.1 is marginal, but the alternator is new and the running voltage is in the 14.5 range.

 

No starts and dying sounds like a fuel pump driver module. Does the van have one?

 

It does, and it was one of the first things I tried. Made no difference so I returned it - mine was ok. Tested CMP today and it checked out, also grounds to relays. The search continues....

 

Tested CKP today and it checked out as well, however, I did discover that the wiring had been repaired before (well known wire routing issue that has caused many problems for Ford owners). It looks like a repaired area on the harness right against the A/C compressor - which I have not taken apart to inspect - yet. Also found the harness had been opened and accessed right at the PCM. I saw this before as it looked like there was a splice and I got excited, hoping to find a problem. Unwrapped the wires that had been taped and there was no splice, but it makes sense as it was probably accessed for troubleshooting the exact same problem I'm experiencing now. This circuit is shielded and I'm wondering if the area that has been left unshielded is enough to cause some interference????

 

One more puzzle piece to report - on the last shutdown of the engine, I left the key in the on position and pulled these 2 DTC's. P2106 and P061B - "An intermittent CKP sensor or harness concern may cause P061B to set. Check for intermittent CKP sensor and harness concerns". This is what caused me to further investigate the CKP sensor/circuit.

 

A running voltage of 14.5v is high.
All my cars have a running voltage in the 13.1-13.4v range.
A voltage of 14.5v is a high charge voltage and is used when a battery is low.

 

Some vans where equipped with 2 battery's, the other being on the passenger drain rail. When one goes bad it can also make the other go bad and give a big spike in amps. Might want to see if yours is equipped with another battery.

 

Just one battery, and I believe the running voltage last time I noticed was 14.1