Hard Start Fuell pressure problem

[Griceok]

2005 Ford expedition. Extremley hard to start. Sometimes have to crank for 10-15 minutes. Usually when cold. Finally starts and runs runs fine.

1) changed fuel filter
2) changed fuel rail pressure sensor
3) changed fpdm*
3) changed fuel pump*

None of the above worked. Seems like it may be a relay but according to the manual fuel pump relay is not serviceable.

Throwing code p0191 (which of course tells me to check all the above).

I've searched and seen several trucks with same problem but never the resolution. Stumped.

 

[rburch]

I would say COP since you have changed everything fuel related. Check them to see if any of them are cracked on the top, if any are replace them.

 

[flyin]

just a thought, cyl head temp sender or harness

 

[Griceok]

Turns out it was the central junction box. Actually the starter relay but had to replace the entire fuse box as the relay is not serviceable. 8 dollar part costs 200 to replace.

 

[flyin]

Is the windshield leaking? It was common with cjb failures.

It doesn't take much for a little water to run down some harness

 

[Griceok]

Thanks for noting. I hadn't noticed it leaking but sounds like I need to check. I don't want to go through that again.

 

[dphelps34]

I had the same issue with my 2005 Exp. I had been troubleshooting this for months replacing the fuel pump driver module, fuel pump itself, and I finally replaced the fuse box behind the right side kick panel. I removed the fuse box and took it apart to find the relays. I inspected the board and didn't see anything that would indicate a problem. I went ahead and bought the fuse box and swapped it out. It took me about 15 minutes. To my surprise, that fixed the problem. I've been running with no issues for a couple of months now. I have never noticed or see any evidence of my windshield leaking but I guess it's possible. Something damaged the relay or may it was just defective.

I bought the part from Autopartscheaper.com for $369. Here's the link to it. Good luck to you. This should solve the problem.

https://www.autopartscheaper.com/2005-Ford-Expedition-Fuse-Central-Junction-Box-p/5l1z-14a068-ba.htm