Fuel Pump and Lean Conditions

[nickname23]

2004 3.0 OHV V6 GAS not FLEX

The gas part is important...

Previously mentioned my trucks little adventures..

O'Reilly's Part Number A30088
Went through three warranty returns, this is partially my fault and also the manufacturer/inventory system that Limited Lifetime Warranty gets you.

Every single time, boxed A30088 however...

Labeled Precision Fuel Pumps but with part number
P76122BD which is Carter Fuel Systems

This pump will burn out very quickly, it is also Flex-Fuel these pumps have a different color sock and parts which are BLUE instead of WHITE & ORANGE/BROWN for GAS

When I first started turning a wrench Flex Pumps weren't common...

So this third pump basically has been on life support, after fixing even more of the truck I decided to Frankenstein my old fuel pump which was the original one before all this...

Sacrificed a Fuel Sender unit off RockAuto that was wholesale so no loss, it definitely did it's duty please give respect to the dead ☠

I basically rewired and created the connections, it died but answered more questions. Realizing my blunder because we are all human and roadside fuel pump replacement is stressful..

O'Reilly's Limited Warranty selected this part because it's near identical and isn't even listing GAS or FUEL but shows blue sock & coloring..
Eventually got the correct one that's shown in the picture when you pull the A30088 number in their website.

What's interesting is the boxing feels like a total scam / failure of updating and listing parts specifications indirectly or lacking something as serious as FUEL TYPE.

I get you can use some Flex Pumps but that doesn't mean they will work for that engine, hell it died 3 times on me.

Good thing is any water left in my fuel system is out because of this overlook and issue with the manufacturer.

Bad news after fixing this, truck runs great again but....

Short Fuel Trim is +18-20 idle with the occasional -10

Long Trim +30.5

Think my gaskets are screwed, vacuum leak which is causing difficulty but not impossible engine startup.

Weather has been great here, probably the best days I've been stranded hell I fixed this in front of an old church near were I live, nobody around just people and nice weather all to myself.

*Edit*
O'Reilly's honored everything, only purchased once no real hassle.

 

[flyin-lowe]

All I can tell you is I ordered a Bosch fuel pump from Rock Auto. Bosch made the OEM pumps for Ford according to the rep I spoke with. I damaged the pump installing it so I grabbed one from Oreilly because I needed it that day. The Oreilly one was all over the place on the fuel gauge so I ordered another Bosch from Rock Auto and took the one back to Oreilly for a full refund. The Bosch has been in for a couple months and zero issues and the fuel gauge is right on. Plus the Bosch was almost half the price of the ones at Oreilly.

 

[Curious Hound]

Need to check fuel pressure.

 

[nickname23]

Really appreciate the replies.

So far the truck starts reliably but long cranking, sometimes requiring a second prime.

By that I mean turning the key off and on once.

Fuel pressure seems good enough to start and operate however my gaskets are definitely bad

New pump is running great, strong no hesitation I can even power shift the gears again.

Not pushing my luck, no longer using starter fluid, it just smokes through the intake and floods anyways.

Is my truck having the intake port issue?

Oil is fresh, no contamination no coolant leak.
Hell the only thing is a weeping pan and power steering housing....

Beautiful days, one minute I'm kicking myself and the truck but then it's usually not a big deal.

Anyone can link me some info on replacing the throttle and intake? I can send pics...

I've only done the 4.0..

 

[nickname23]

All I can tell you is I ordered a Bosch fuel pump from Rock Auto. Bosch made the OEM pumps for Ford according to the rep I spoke with. I damaged the pump installing it so I grabbed one from Oreilly because I needed it that day. The Oreilly one was all over the place on the fuel gauge so I ordered another Bosch from Rock Auto and took the one back to Oreilly for a full refund. The Bosch has been in for a couple months and zero issues and the fuel gauge is right on. Plus the Bosch was almost half the price of the ones at Oreilly.

Food for thought, definitely had good experiences with Bosch myself.

I wish this will help anyone else do they don't go through what I did

 

[nickname23]

Need to check fuel pressure.

Fuel Pressure is enough to start, but very lean especially on cold start so it sometimes takes a second.

Occasionally it may start with a very low idle but no issues pumping the gas pedal and getting him going.

Definitely babying this pump until I get new gaskets and would appreciate any wisdom on doing so, throttle body is plastic unfortunately.

 

[nickname23]

Maf is over 3 g so it's fine? actually from an explorer because my old one was fried

IAC is working, oil still sometimes showing up in throttle body past PCV.

Real sticky stuff, but engine running good no smoke clean no more gas smell either.

Cleaned PCV new fuel filter.

Isn't there an issue with this motor requiring two sets of intake gaskets and they can fail
Or something about it's not common information so people install only one but then it eventually fails because it requires both...

 

[nickname23]

Topped coolant off, minor smoke after startup.

Intake gaskets definitely showing the beginning stages of failure and truck performance is much better regardless of lean codes due to warmer weather.

Good news is the head gasket is solid 100% after burping no bubbles or air in radiator or expansion tank & heater core works cooking you like a rotisserie chicken .

No oil & coolant so the intake and throttle is shot causing too much air and minor coolant leak on cold startup.

Also reminded I'm human, pump works like a clock but realized it's defective, had to repair the fuel level bobber to get it to properly secure.

Ran out of gas

 

[SmittyAlford]

Really appreciate the replies.

So far the truck starts reliably but long cranking, sometimes requiring a second prime.

By that I mean turning the key off and on once.

Fuel pressure seems good enough to start and operate however my gaskets are definitely bad

New pump is running great, strong no hesitation I can even power shift the gears again.

Not pushing my luck, no longer using starter fluid, it just smokes through the intake and floods anyways.

Is my truck having the intake port issue?

Oil is fresh, no contamination no coolant leak.
Hell the only thing is a weeping pan and power steering housing....

Beautiful days, one minute I'm kicking myself and the truck but then it's usually not a big deal.

Anyone can link me some info on replacing the throttle and intake? I can send pics...

I've only done the 4.0..

New member - 1st time owner - 98, 3.0, 2wd. Reading thru this thread I will be doing a Bosch pump. Ordered a fuel pressure tester today. But think I have a weak fuel pump issue. Starts after 2-3 attempts. Runs very rough (almost dies) then kicks in - then rough - almost dies - repeat, repeat until finally runs smooth, Touch the gas and it wants to run rough again. Soooo being a little "older" will I need to remove the bed? Or is there a better way?

Note: recent work - MAF & IDAC cleaned, checked vacuum lines (fixed one), plugs, wires, coil pack, air filer & cleaned out the air box.

 

[fixizin]

... roadside fuel pump replacement is stressful...

I'll say!... did you drop the tank or remove the bed?

 

[nickname23]

... roadside fuel pump replacement is stressful...

I'll say!... did you drop the tank or remove the bed?

Always rawdog the bed, it's fiberglass not real so more awkward than heavy.
Or something like it, if it was real steel like my white one then no because after doing that yeah dropping the tank seems better.

 

[nickname23]

There will be an update, this is AFTER lightly cleaning by hand..

 

[nickname23]

New member - 1st time owner - 98, 3.0, 2wd. Reading thru this thread I will be doing a Bosch pump. Ordered a fuel pressure tester today. But think I have a weak fuel pump issue. Starts after 2-3 attempts. Runs very rough (almost dies) then kicks in - then rough - almost dies - repeat, repeat until finally runs smooth, Touch the gas and it wants to run rough again. Soooo being a little "older" will I need to remove the bed? Or is there a better way?

Note: recent work - MAF & IDAC cleaned, checked vacuum lines (fixed one), plugs, wires, coil pack, air filer & cleaned out the air box.

Just recently got a Delphi to replace the last one I put in, other issues causing it to fail..
You can remove the bed, not entirely but it can be worked towards to rear giving some but limited room to work.

Replacing the pump can be tedious but only if you let it, always completely fill the tank and I'd leave time for it to sit submerged for awhile.

Prime it a few times, there is a test valve on the passenger side of the injection systems fuel rail, make sure it is getting fuel before cranking.

Apparently this was an issue that popped up on Reddit YEARS ago with cheaper fuel pumps so maybe there are a few bad batches combined with a faulty design?

Rockauto is proving valuable to the independent owner, Motorcraft is definitely expensive but I can see differences within the price range, from completely different wiring and connections to thinner plastic and even thinner caps for storage and shipment.

We'll see how Delphi holds up and lemme know about Bosch, heard good things.

 

[nickname23]

Passenger side middle ports valve is not sealed, will post heads soon on the side but I'm letting the valves soak in cleaner before I take the exhaust manifolds off and head gasket.

Every port that allows me to see a valve holds cleaner, so that valve must be so gunked up it's no longer seated correctly. Engine doesn't fail to compress but that will always be a occasional misfire...

I'm going to have to clean everything, oil and carbon in intake, coolant passages were coated in rust.

So far surprisingly no leak in the gaskets, maybe not torqued properly?

Replacing exhaust manifold bolts, there is the usual missing broken bolts on each side because someone decided brute force would work

Head gasket looks like it's in one piece but I'm going deeper..

Two Rocker arms slightly loose on passenger side but functioning.

 

[nickname23]

One Head off and surprisingly it looks worse than what it is.

Boy did the bad catalytic converter make a HUGE mess!