New to mustangs but I am an automotive tech, I have an 04 gt that over pressures during priming cycle koeo (90psi), once started it holds perfect fuel pressure. The car has seen internal moisture so I replaced frp sensor, ecu, fpcm, and a failed fuel pump from symptoms.. question is does anyone know own exactly how the ecu controls the fuel pump during priming?
Crazy fuel issue lifting fuel rails
- Thread starter greenhornponyguy
- Start date
More info: bone stock 4.6 with 65k on the car, there's not much I can't figure out but this one has me stumped... koeo fuel pressure spikes to 90psi resulting in lifting fuel rail off of injectors and pouring fuel all over the engine. FYI convertible car that has, im sure seen moisture since I live in the PNW... is there connectors inside the car somewhere under the carpet that I havent found ect?? All the usual suspected connectors are clean and corrosion free...
Ever get this issue fixed? I’m experiencing the exact same issue on my 2003 GT. Ford told me I’m missing all the fuel injector retention clips, but this is my 3rd New Edge Mustang and I’ve never had clips on any of them (my first was an ‘01 I bought new, so they couldn’t tell me someone removed them). I’ve blown 7 injector o-rings over the past 5 months, always due to a fuel pressure spike on cranking, and it lifts and bends my fuel rails, as well.
Yes, the injector retention clips solved my 03' GT fuel rail problems. As I noted, these were NOT installed on new SN95 'Stangs from the factory, despite my local Ford parts and service departments arguing otherwise (try to find a pic on-line of a 4.6L modular with them installed... you won't find any). It is very clear to me that Ford realized the problem here long after the last New Edge Mustang rolled off the assembly line in 2004. They made clips and added them as a normal part in their parts diagrams (as though they were installed at the factory), then silently swept the issue under the rug. Shame on Ford here, as they really should have recalled these vehicles and installed them since this is a potential fire hazard and risk to human life.
Note, though, that these appear to have been hastily made. While they really should be bent at a 90-degree angle, they are closer to 95 or 100 degrees, so they won't just fit nicely out of the package. When you buy them, expect to have to place the longer ends into a vise and gently tap the shorter ends down to 90-degrees before you install them on your fuel rails. Also, my local dealer wanted to charge me $10 apiece for them, but I found them on-line from other Ford dealers for half that, so I ordered them on-line. I would also recommend you ensure the fuel rails are not bowed at the centers and that the two mounting brackets on each side are still at 90-degrees. I removed the 4 bolts (2 on each rail), popped out all the injectors, re-installed the 4 bolts, gently tapped the rails near the mounting brackets to get them back at 90-degrees, then gently tapped the center of the rails to get them straight again (use a clean, thick, metal straight edge to test for rail straightness). Then I removed the bolts, reinstalled the injectors with fresh O-rings, remounted the rails, installed all the new retention clips (properly bent to 90-degrees), and haven't popped an O-ring since. I hope this helps you and others.
Unfortunately, Ford really did drop the ball on this one, and my respect for them wanes as they continue to make poor decisions like this. As there are now fewer SN95 and New Edge vehicles on the road, the problem is just fading into silence. Meh.
Copy that!! I will give it a try.. have you watched your fuel pressure on cranking to verify it wasn't too high of fuel pressure? Mine shows the 90 psi max of the fuel rail pressure sensor. That doesn't seem right to me. I made my own fuel rail hold downs and it stopped lifting the rails but I still get a 0193 code for frps high input once in a while.... thanks again for the reply and the detail!! Guess I will run it until something else fails and gives me more clues lol
Well, I have an Autometer fuel pressure gauge installed. I did notice that it spiked high (90, too) on crank, and it only ever blew injector O-rings on crank (never while actually driving), but around that time I noticed a grounding issue with that gauge. It was also around that time that I installed the injector clips (maybe two weeks apart). That said, it's difficult to tell if the pressure spikes were real or due to the odd grounding issue I had with the gauge (actually, all 7 of my installed Autometer gauges, as they all had odd issues and do not now). However, I do suspect the pressure issues for me were real, as about two months ago, I cranked my GT to a no-start condition. It cranked, and I could hear the fuel pump priming, but no fire up. I disconnected the fuel rail connection near the entry point of the rails and primed the pump, but no fuel. I knew the filter was good, so I looked for kinked lines quickly, then realized, "How in the world would I have a kinked fuel line anyway?!?". So, I abandoned that idea and disconnected the fuel line at the fuel filter inlet and primed again. No fuel. So... the pump was turning, but not pushing fuel. My GT is my only car (my wife was at work with hers), so I donned my running clothes and a backpack and ran 3.9 miles to OReilley's. Bought a fuel pump, then had to walk back since the box was way too big to fit in my backpack! Oh, well. I dropped the tank and removed the pump to see that the outlet hose of the pump had been blown off of the metal tube, and there was no clamp for it. My new pump had a crimped clamp on it, so I felt better about installing it. So... yes... I do now wonder if I had fuel pressure issues on crank, as I really don't see my pressure gauge hit 90 like it used to. Forgive the TL;DR. Have a good one!
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