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2.3L ('83-'97) Low fuel pressure, code 411, and other potentially unrelated problems


tinoracha

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I am having rough starts and engine bogging / stalling issues.

I've done a great deal of parts replacing and at this point I feel I am chasing my own tail. Recently after doing a KOEO test and getting code 223 & 224 I replaced my ICM. This cleared the codes and my check engine light but now my engine is bogging and having a hard time starting, at a frequency of every second or third start. I checked my fuel pressure and with the ignition on only got it up to around 8 and running was around 20psi, which bumps up to 30 with the vacuum hose off. In protest I replaced my fuel pressure regulator and fuel pump and now my fuel pressure reading is 20 with the ignition on and 30 ish with the engine running (I believe it is supposed to be 40). The fuel pressure drops about 2 PSI over 20 minutes with the engine off.

A few other notes / potentially confounding factors:
- engine has white smoke on start up that seems very wet (not coolant)
- I recently installed a catch can into the PCV line

I tried a KOER test this evening and was meet with the code 411 which is "cannot control RPM during ER low RPM check". I cleaned my IAC and tested it by listening to the idle with and without it plugged in and it seems to be working properly.

Anyway, I would be very grateful for any suggestions on where to look to fix my hard start + stalling issue. I don't have very much experience working vehicles so any and all input is welcome!
 

franklin2

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Did you forget the fuel filter in your list?
 

tinoracha

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Another note: when replacing my fuel pump I noticed some cracking in the fuel filler hose. Could this lead to a drop in fuel pressure? It doesn't smell like gas...
 

franklin2

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Next thing I would do is make sure you have a full 12v to the pump. The only way to make sure is put a meter on it back at the sending unit. I know though, it's hard to get to. I am wondering if you have a poor ground or poor elec connection reducing the voltage to the pump?
 

tinoracha

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I tested voltage and took more fuel pump readings, here's what I found:

with the ignition on:
pink: 6.7 Volts
Yellow 7.9 volts

Engine on Cranking:
Pink: 10.5 - 11.8 Volts
Yellow: 6.7 Volts

The fuel pump with the ignition on reads:
25psi into the fuel rail (downstream of the fuel filter)
4psi return line

Engine running:
30psi in
4-5psi return


Could a fuel injector issue cause this? I listened to them all and they are all firing at idle.
When I installed the catch can I cleaned the outsides of the fuel injectors and inspected them, the o-rings looked fine so I didn't think to replace them.
 

franklin2

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The pink is the pump, the yellow is the sending unit for the fuel gauge. Black should be the common or ground. Are you using the black for the black lead of your meter? I would, to make sure your ground is good also. That is what the pump is using. Here's a diagram.
 

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tinoracha

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Thanks for the diagram! Where did you come by it?

I ran a jumper cable from the negative battery post to use as my ground. Is this kosher?
 

franklin2

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Thanks for the diagram! Where did you come by it?

I ran a jumper cable from the negative battery post to use as my ground. Is this kosher?
The diagram came from my local library.

Not really kosher. You have a nice ground for your meter you made up with a jumper cable. But what if your ground to the pump is no good? Unless you want to make a new ground and tie that into the pump ground. Would be a good test.
 

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