2.4 140 ps working problem

[aReddington]

Hello,
I’m working on a 2.4, 140 hp, rear-wheel-drive minivan.
The engine cranks longer than usual, but it usually starts. After running for a while at idle, the FRP pressure fluctuates and the vehicle stalls when the fuel filter is about half-empty. After that, I have to refill the filter and try a few times with easy starting. Sometimes it runs without any problems for hours; other times it’s a nightmare.

Work done:
- Fuel filter cap replaced
- A new injector tried
- Completely new high-pressure pump installed
- FRP-VCV replaced
- Cam and crank sensors replaced
- Fuel tank fully cleaned
- Hoses from the tank to the filter head replaced
- Hose from the filter head to the fuel pump replaced
- Software updated to the latest version

If you have a better idea, I’d appreciate hearing it.

[aReddington]

If I need to add any updates:
- There are no DTCs at all
- During the drive, everything was normal
- CMP and CKP timing are normal
- The non-removable parts of the fuel lines (the returns) were removed and inspected; no cracks or leaks were found
However the problem persists.

[knobby1]

If I need to add any updates:
- There are no DTCs at all
- During the drive, everything was normal
- CMP and CKP timing are normal
- The non-removable parts of the fuel lines (the returns) were removed and inspected; no cracks or leaks were found
However the problem persists.

Why was the pump replaced..?? They never play up. Were the learns done when the pump and SCV/PRV were replaced, were they Genuine Denso/Ford Items..?? When was the fuel filter last replaced..??

If the filter is emptying itself, you have air ingress. Filter heads are known to crack and let air in.

Lord Knobrot (Smithy)

[aReddington]

If I need to add any updates:
- There are no DTCs at all
- During the drive, everything was normal
- CMP and CKP timing are normal
- The non-removable parts of the fuel lines (the returns) were removed and inspected; no cracks or leaks were found
However the problem persists.

Why was the pump replaced..?? They never play up. Were the learns done when the pump and SCV/PRV were replaced, were they Genuine Denso/Ford Items..?? When was the fuel filter last replaced..??

If the filter is emptying itself, you have air ingress. Filter heads are known to crack and let air in.

Lord Knobrot (Smithy)

The fuel pump housing may be worn from high mileage, so they replaced the pump because it wasn’t delivering enough fuel. The fuel filter used is the original, but the filter head is from another supplier.

[andz327]

Possible faulty injector or the leak back green O‐rings worn and drawing air

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