'00 dead, seems fuel system problem

[pstrbrc]

This seems to be a recurring problem with a small percentage of Windstars, but I can't find anybody with a 100% solution.
My story: The Windstar started a momentary "running like crap" that would, in a few seconds, disappear as fast as it came. It got to the point that it would run like crap, die, and maybe or maybe not restart. Finally, it just died. No codes, so I suspected the pcm. (If it runs like poop, if it just quits on you, and the brain doesn't remember this happening, logic sez it's the brain, right?) It died 40 miles away from home, parked in some weeds, so after a "reman" pcm from Standard by way of Rock Auto (did I mention that the weed patch 40 miles away was in the panhandle of Oklahoma?) (And, how do you "reman" a pcm? Inquiring minds want to know.) made absolutely no difference, I ignored it for the rest of the winter, and well into the spring. I read that fuel pump wiring on these was suspect, so I went through the bother of draining the tank and dropping it, just to check this out. (Cars only die on me right after I fill them up. 26 gallons. What a pain.) Wiring seemed fine, pump seemed to function just fine with a 12v jump, so I buttoned it up, and let it set for a couple more months. I borrowed a trailer and drug it home last week, and here's where I am:

OK. Diagnosis time. Carb cleaner sprayed into vacuum port for fuel pressure regulator-runs, but crappy, assumed vacuum port made for lousy mixture control. Did it a second time w/someone else at the ignition switch, ran the way I would expect w/ my spraying controlling the mixture. OK.
Light wired into jumpers to FP harness. Turn on ignition. Comes on briefly (very briefly, much shorter than a sec.) and goes out. =/ Pump doesn't run. No pressure at fuel rail.
Jumped 12v directly into FP wiring harness. Pump noticeably runs. Let it run for `30 sec, heard gas splashing back into tank, so fuel rail is purged of air. Produces 38psi @ fuel rail. With pump jumped, running, & 38 psi, attempted to start. Cranks, but doesn't fire. Not even a hint of an attempt at combustion.
My conclusion: Fuel pump works. Ignition works. Neither pump nor injectors are receiving appropriate signals.
I still have the original pcm, and am tempted to swap it back, but it was what was in the van when it died, so...
I have replaced the fuel pump relay and the pcm relay (that one with a 40a bosch-type I always have on hand)
Fuses 1,2, and 5 have been checked repeatedly, then replaced w/new.
Found a thread "out there" that claimed to fix this with a new pcm diode, but the diode tests out, so I'm not persuaded to waste money on one of those.
So, what's wrong? What do I check next? What have I overlooked? Anybody?

Edit: Somebody "out there somewhere" mentioned similar symptoms, and claimed to fix them by jumping the starter interrupt relay. I thought that was connected to the security system, having to do with the chip in the key, and that it just wouldn't let the starter turn over. Right?

[autojoe]

only dies after fill up?when it wont start.....fuel pressure?spark?injector pulse?need more information.

[autojoe]

3.0 or 3.8 engine?

[12Ounce]

Fuel supply ... plain and simple. Just because the pump motor runs ... doesn't mean the pump works as it should. Lots of little pieces in there to fail.

Fuel pump issues often do not generate codes. The PCM is not suspect ....if the engine runs when you spray in starter-fluid! That vindicates everything but the fuel supply.

Replace the pump (with new!). Replace the in-line filter. Remove the injectors and give the injector inlet screens a side-ways blast of aerosol brake fluid ... do not do anything else to the injectors .... no soaking, nothing. Replace the fuel pump relay and PCM supply relay with new ones.

[pstrbrc]

Originally Posted by autojoe

only dies after fill up?when it wont start.....fuel pressure?spark?injector pulse?need more information.

(sigh) No, EVERY car that's ever broken down had just been filled. Murphy's Law.

[pstrbrc]

Originally Posted by autojoe

3.0 or 3.8 engine?

Oh, yeah. Did anybody actually buy a 3.0 in '00?
3.8L.

[pstrbrc]

OK, never mind. D--- thing started this afternoon.
After everything I've done, all I did was swap back to the original pcm.
Immediately had ~40psi at the fuel rail, so went ahead and turned the key one notch further... vroom. Runs like a champ. Smooth idle, no hesitation, good power all the way past legal speed. (sigh) But I still don't know why it quit, nor why it's running now.
Here's a list of everything I did:
replaced:
Fuel pump relay
pcm relay
All engine-related fuses in the power center under the hood.
Cleaned all contacts w/electronic cleaner, blown out with compressed air, and dielectric grease on everything.
Dropped the tank, unhooked all the connectors on the fp assembly, cleaned and greased them, put everything back. Took all the connectors apart that I could find and reach, cleaned everything with electronic cleaner, greased 'em and snapped them back together.

Charged up the battery (been sitting for ~8 months!)

Didn't run before. Now it runs. Never mind. Just wish I knew what was wrong, and what fixed it.

[12Ounce]

Originally Posted by pstrbrc

:..................Charged up the battery (been sitting for ~8 months!)...........

You done a lot of good work! All that cleaning and lubricating will bode you well!

There is a good chance that low voltage played a role along the way ... perhaps keeping some relay or other circuit not fully employed.

Much better to wonder why it runs ... than to wonder why it does not run!

[northern piper]

Much better to wonder why it runs ... than to wonder why it does not run!

now THAT's the quote of the week!!