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Hello,
I have a 2004.5 having trouble at first start with fuel pressure. I first started feeling slight bucking and rough idle every so often, about once a month and would seem to return to normal.
I installed a fuel pressure gauge to see how low it went while having problems. When I installed I noticed it was under 40 psi. Next step I installed an Ford blue spring kit. I questioned where to put the o ring at the black insert that 2004.5's have. Ive tried putting in first placing it in the hole, and I've tried putting it on the black piece. It's very tight when on the black piece and you really have to force it into place. When I put it around the black piece, I get 80 psi. idle, but not until it warms up for a couple miles. It would go down to near 0 while driving the first few minutes. So I tried again placing the o ring in first, then the black piece. Now it starts idling at 40 psi, but drops to near 0 while warming up the first few miles. Then it will be steady 60 psi even at WOT. Starts the same way each time, even when only shut down for a few minutes. While having issues the FICM is always 49 volts. The HPOP is 580 psi idle, up to 2450 when raising the rpm. IPR is 22% idle, up to 63%. MAP is 0.8 psi idle, then up to 9.1. Using torque pro.
So, not 100% sure I'm doing the blue spring correctly, but it seems to be the same problem even before the blue spring install.
I'm considering a new fuel pump. Also, I know the fuel pickup or filter in the tank is messed up because right below 1/4 tank is empty. I just don't know if that would cause a full tank to have pressure issues. I've replaced both fuel filters with OEM once a year since I've had the truck in 2015. They should only have about 5000 miles on them now.
Any ideas or help is appreciated.
The blue spring kit has extra parts in it so that it can cover all the years on the road.
So it the part was not there when you took it apart then you don't need to put it in.
1/4 is the point where a missing valve in the pickup foot will show that it has fallen out.
The red duck bil can also fall off. That is more likely to give air in the fuel.
You can see in the two larger photo the little bypass valve and that has been talked about when it comes to fuel issues lately. Also on the bottom of that foot there is a screen and
it can get crap on it and plug up and restrict flow. If you go into this album you can look at the full tank parts. I have the tool shown for removing the tank ring the easy way. I feel if you
in the tank then you should replace the top seal ring. It's a big green square side ring. You can also do the harpoon mad to get a bit more fuel into the tank faster without it burping
diesel back at you. The tank ring tool is a bout $30.00 on Ebay last time I looked.
The black retaining piece goes with my truck, just wasn't sure about the o ring. I don't remember seeing the o ring while removing the original. I appreciate the photos and will order the sending unit strainer and screens. I've seen the harpoon videos and looks like a great reason to drop the tank as well. For now, I'll just baby it the first few minutes until it builds enough pressure.
Thanks
Made it to work this morning, took awhile before pressure would stay stable at 60 psi. Tried starting an hour later with no luck. Had to pull into a parking lot. Tried re-seating the spring a few times and still no pressure. Picked up a new fuel pump. Easy 20 minute job. A little bit of diesel bath. Didn't plan on doing this in a middle school parking lot. My pressure is pretty steady at 60-65psi now. The new pump doesn't have the fuel heater. Anyone run into this before? No place to plug the 3rd connector. Was pretty happy just to make it home, but I'll order another pump if needed.
Your new pump should have supplied a New pigtail for your pump. They discontinued the heater on those pumps. I to was baffled when I put mine in. Took it back to Napa and they didn't have a clue. If I remember correctly it was Sean or Mark that filled me in here on FTE.
I went up to Napa and filled them in on that tid bit of info. They where appreciative for sure.
