2003 Expy died... Help!

[NCDeere]

Hey folks. I've seen other threads talking about fuel related break downs and I have another one. My wife's 2003 Expy had died on us twice. Once with her and once with both of us. For her, it died, then started up after about 15 mins. For us it died after filling up with gas. I started it up, then moved about 3 feet when it died. And it would not start back. It acted like it wasn't getting any fuel. So we had it towed to the Dealership. When it got there, the Service Technician cranked it right up... no problems. They kept it for two days trying to find something out but didn't. We had already had the fuel pump changed recently so hoped that wasn't it and they said it was fine. So the technician said he thought it might be the fuel pump relay but he wasn't sure. He said he would have changed it but it is soldered to the board... is this right? Where is the fuel pump relay and is it soldered? How do I change it? Another thing I noticed this weekend is that the info center that shows MPG has steadily declined... a week or so ago I noticed it was about 12.3 MPG, which is lower than normal. This weekend, I noticed it now says 9.0 MPG... what the heck? Can you guys give me an idea why this could be...

This is just driving me nuts... this is the vehicle that carries my wife and kids and I want it to be reliable. Up to now, it has been.

Please give me some ideas of what I can look at. Items recently done were the fuel pump (pretty sure they changed the fuel filter also), spark plugs, new air filter...

Thanks,

Bryan

 

[Spoon-Man]

It sounds like the same thing that happend to mine. I had some dirt and other things in my gas tank that was clogging up the lines. one the truck started moving it would get sucked up into the line an stall out the truck. After it sat for a little bit it would start up like nothing was wrong. I droped my tank and cleaned it out, the replace all my fuel lines. Been running great ever since.

 

[NCDeere]

HMMM... that could be... I wondered also if I could have bad fuel... maybe water or dirt in the tank... I need to look at that more closely and see if I can find anything... How did you come to the conclusion you had dirt in your tank??? or did you simply find it in your troubleshooting???

Thanks for your input.

Bryan

 

[Stoned06]

How many miles? When was the last time the Fuel Filter was replaced? It definately sounds like it is starved for fuel, so a clog somewhere or a bad pump (but that was just replaced so I doubt it). Have the injectors ever been cleaned or treated with fuel additive?
I would start with the fuel filter and a fuel system treatment/cleaner since those are cheaply and easily done. If it still does it, then I would tear into what was mentioned above. Good luck.

 

[Spoon-Man]

HMMM... that could be... I wondered also if I could have bad fuel... maybe water or dirt in the tank... I need to look at that more closely and see if I can find anything... How did you come to the conclusion you had dirt in your tank??? or did you simply find it in your troubleshooting???

Thanks for your input.

Bryan

I pulled the tank out to put in a new fuel pump and looked inside with a flash light, after fishing the frash light out from dropping it inside the tank I seen lot of dirt an what looked like little speks of rust.. So i dumped the gas out into a oil can and washed it out wish water till it was clean.

 

[NCDeere]

How many miles? When was the last time the Fuel Filter was replaced? It definately sounds like it is starved for fuel, so a clog somewhere or a bad pump (but that was just replaced so I doubt it). Have the injectors ever been cleaned or treated with fuel additive?
I would start with the fuel filter and a fuel system treatment/cleaner since those are cheaply and easily done. If it still does it, then I would tear into what was mentioned above. Good luck.

I actually did add some fuel additive this weekend. I'm going to probably do that again next fill up. I am also going to verify the filter was changed when they pump was replaced.

Thanks.

 

[NCDeere]

Looking in the manual, I see a fuse #34 (20A) that provides protection for the following:
PCM, Fuel injectors, Fuel pump
relay, Fuel pump shut-off switch,
Fuel pump motor, Idle air control
(IAC) solenoid, Mass Air Flow
(MAF) sensor

Then I find Relay #303 (Fuel Pump Relay) which is for:
Fuel pump shut-off switch, PCM
(fuel pump monitor), Fuel pump

But it also says: Note: Relays R301–R305 are not serviceable components; see your dealer or a qualified technician for assistance.

So when I read on this forum that guys are changing out their fuel pump relay are they changing out this relay? The dealership said it is soldered onto the control board and he cant change it without replacing the board. What am I missing here? Are the guys on here de-soldering the relay and re-soldering a new one on? How do you actually change out the fuel pump relay? Just curious...

Thanks for all of your input so far...

 

[Eric]

Thought I would share something similar a friend of mine experienced. His 98 was doing the same things you describe, they concentrated on the fuel as well but after countless tows to the shop and lots of replaced items it turned out to be the "PATS" security system. Apparently the chip that reads the key code was shorting out and would shut the engine down or not start. Once they fixed that it has been fine ever since.

 

[ELVATO]

Drop your spare. I think that's where the fuel module thing (forget the actual name is) is. At least that's where it is on the F150s. I know it goes out randomly on those because of corrosion. Something about the aluminum case of the module reacting with the steel from the frame (since it is bolted on to the frame.) When that goes, the truck won't start since that is what controls the fuel supply (at least on the F150s.)

If anything, check your spare tire pressure while you have it down. It's one of those often overlooked items

 

[NCDeere]

Drop your spare. I think that's where the fuel module thing (forget the actual name is) is. At least that's where it is on the F150s. I know it goes out randomly on those because of corrosion. Something about the aluminum case of the module reacting with the steel from the frame (since it is bolted on to the frame.) When that goes, the truck won't start since that is what controls the fuel supply (at least on the F150s.)

If anything, check your spare tire pressure while you have it down. It's one of those often overlooked items

I will check that fuel module(?) by dropping the spare... and you're right, I'll check the spare pressure while its down... most people do forget to check it now and then...

Thanks.

 

[NCDeere]

Well it has happened again... we went out to go to the store and it won't start... I also pulled my receipt from when the fuel filter was replaced and discovered they did not change my fuel filter... maybe it's just me but is it not a good idea to put in a new filter when replacing the pump... maybe not.

So I am going to try and change it myself. It's pretty easy on my Powerstroke, but I personally haven't changed this one. I'm gonna look on the site here to see if someone has a "how-to" for it.

I'm also still looking for a "how-to" and info on changing the fuel pump relay.

Relay #303 (Fuel Pump Relay) which is for:
Fuel pump shut-off switch, PCM
(fuel pump monitor), Fuel pump

Manual says: Note: Relays R301–R305 are not serviceable components; see your dealer or a qualified technician for assistance.

So when I read on this forum that guys are changing out their fuel pump relay are they changing out this relay? The dealership said it is soldered onto the control board and he cant change it without replacing the board. What am I missing here? Are the guys on here de-soldering the relay and re-soldering a new one on? How do you actually change out the fuel pump relay? Just curious...

I'll also look into the security system and see if there is anything there...

I guess I'm back to the drawing board... and frustrated...

 

[NCDeere]

I changed my fuel filter last night... it wasn't too bad actually. But when I tried to start it up, it didn't work. It still turns over fine, but won't start. On a couple of tries it sounded like it wanted to start but didn't quite make it. Does the fuel system bleed off any air that might get in it while changing the filter? Just curious (because of the times when it sounded like it was going to start).

So next I'm going to look at crankshaft and camshaft position sensors... what do you guys think?

When Ford had it last, there weren't any trouble codes... so what can go bad and not produce a code??? What do you think???

Any other ideas would be great...


Thanks.

Bryan

 

[NCDeere]

A friend of mine said I need to verify I have the proper psi for the fuel system... I am going to buy a gauge today to check it after work. He said my new (2 months old) fuel pump could be bad or my fuel regulator might be bad.

He said I may want to try changing out my crankshaft or camshaft position sensor also...

This is frustrating...

 

[sngltrck1]

...after fishing the flash light out from dropping it inside the tank ...

That damn near made coffee come out my nose!! LOL

Been chasing electrical demons myself and know the frustration levels.

Sounds like you are getting close though ... good luck!

 

[NCDeere]

So Friday I bought a fuel pressure gauge to see what I had... The book I have said it should have 55psi whether cranked or not... So I connected the gauge and turned the key to ON and the gauge read ZERO psi... nothing... So my thoughts were it is either the fuel pump (maybe it was a lemon) or it is the fuel pump relay... So I had it towed from the house to the place that put in the fuel pump... They have done some checking and think it is the relay... so the fuse board has to be changed... I told the guy if it does indeed need to be changed, that I want to keep the board... I'll buy another relay and then have spares...

this stinks but I hope we have it figured out...


Bryan

 

[familyof7]

03 expy dying

I'm having the same issues as you did. Did you solve your problem? Here's something strange. Last year our door sensors stopped working and then our fuel pump went out. We had both fixed. This past month our door sensor started acting up and now our car is dying randomly. Go figure.