Fuel pump woes????

[ccool416]

I have a 95 xlt 5.8 e40d bronco...It is not starting. As soon as I turn the key, I notice my fuel pump is not energizing...Hooked it up too my scanner and I get a code 542...any tips and or advise before I get started? I did nothing to it. I went to home depot, shopped and came out. Got in the truck and no start..???

 

[BroncoJoe19]

I have a 95 xlt 5.8 e40d bronco...It is not starting. As soon as I turn the key, I notice my fuel pump is not energizing...Hooked it up too my scanner and I get a code 542...any tips and or advise before I get started? I did nothing to it. I went to home depot, shopped and came out. Got in the truck and no start..???

Code 542... I looked for something obvious... hmmm Ford emblem is missing from front grill???

That don't make sense....

Oh... here it is...

542 Fuel pump circuit failure

From http://fordfuelinjection.com/index.php?p=51

Sorry... just jerking around.

In your truck you have a single IN THE TANK fuel pump/module, and a fuel pressure regulator on the rail.

There is also a fuel pump relay on the left fender wheel well.

Do you have a haynes or chilton's manual? They give a good discription of testing with a fuel guage (if you have one of those)

As you said... you don't hear it when you turn on the key.

You need to make sure that you have power to the pump, and that it is well grounded. OFten bad grounds will cause your problem. If I am reading the wiring diagrams correctly the ground to the fuel pump is located on the left upper radiator support.

You may also want to check to make sure that your inertia switch didn't trip, it is under the dash on the driver's side. The red button needs to be pressed down within the housing.

This issue has been discussed before, and if you do not have a haynes, or chilton's let us know, I have seen others post scanned images of the wiring diagrams for the fuel pump circuit.

joe

 

[blkwlf]

same thing happened to me a few years ago, except i didn't get any codes. had it towed home, put in a new fuel pump worked like a champ. put in a new fuel filter also but waited a day or two so it would collect any debris.

 

[BroncoJoe19]

same thing happened to me a few years ago, except i didn't get any codes. had it towed home, put in a new fuel pump worked like a champ. put in a new fuel filter also but waited a day or two so it would collect any debris.

Should you have to go the new fuel pump route, there are two methods of doing it.

1. drop the tank and install it.

2. cut a hole in your cargo area, and install it without dropping the tank.

IF you want info on the latter method, just ask.

Hopefully it is just a bad connection, or fuse.

Oh.. yeah, I'm sure that there must be a fuse for it.

I didn't look.

joe

 

[BroncoJoe19]

Here is a thread that pretty much covered this issue.

Remember, yours has a single pump,

I think the wireing diagrams are pretty much the same, if not identicle, but the concepts of how to tetst the circuit are the same.

Please let us know if this helps, and post back when you find your solution.

Don't be afraid to ask additional questions.

joe

http://broncozone.com/forums/index.php?sho...fuel+pump\#

 

[Shadow_D]

I've been having an intermittent problem with mine... All I do when this happens is grab the relay on the fender well and bang on it a few times.

I have replaced that relay a few times so I know there is another issue but it might work to get you around till you find the root of the problem...

Just my $0.02

 

[BroncoJoe19]

I've been having an intermittent problem with mine... All I do when this happens is grab the relay on the fender well and bang on it a few times.
I have replaced that relay a few times so I know there is another issue but it might work to get you around till you find the root of the problem...

Just my $0.02

LOL... why don't you troubleshoot it and fix it?

You know it is going to fail when you are on your way to someplace and ther'll be **** to pay if you're late!?

IF grabbing and banging the relay works, it has to be a bad connection. I'm ruling out the actual relay because you already replaced it a couple of times.

You can get a can of CRC electronic contact cleaner in a spray can for acouple of bucks at any NAPA or parts store. Try spraying it into the connector for the relay, and check your grounds, inparticular the one on the upper left radiatior bracket.

LOL... I hope that motivated you to take a wrench to your baby this weekend.

Have a great day!

joe

 

[Shadow_D]

Hey Joe :lol:

I know I need to get on this along with a few other things. The relay burns out before I replace it so it might be a bad ground but I'm not sure yet. I have a bad wheel bearing and the Beast is just sitting right now till I get motivated to get it fixed :lol:

 

[miesk5]

yo!

DTC 542 (KOEO & Memory code) Fuel pump circuit open; PCM to motor ground

DTC 542 (KOEO & Memory code) Fuel pump open, bad ground or always on

EDIT: ck FP relay and sockets for corrosion or open conns.

ck EEC PWR relay for same

 

[Big_Ford_POS]

A heads up for you guys... I got stranded at an intersection when my truck just stalled. I noticed in the past few days if I hit a bumb the truck bucked like the filter was clogged and sometime it was ramdom but it last a second or two. Well after I got it towed home and *after* I replace the pump and filter. It still wouldn't get fuel and no power to the pump. I grabbed the relay, to inspect it, with the key on and it clicked and the pump primed. Come to find out the female connectors in the plug of the relay were corroded and the main power finally seperated but yet it stayed in the plug making a intermiten connection. It probably seperated when I touched it to inspect it. The dealer sells the "pig tails", all you do is splice them in. It wasn't every much I think like $8-10. And while your at it do the ECC relay pig tail also becuase your injector pulse is controled through that and I think power to "energize" the fuel pump relay. So its a good preventive maintenance item. I was also considering faburcating a fuse panel and replacing all the fusible links. Anyone heard of that or looked into it? Anyway just a thought to give you guys something to think about...

 

[miesk5]

Big,

yes, I know some have replaced Links w/fuses; esp the one from alt to starter relay

Some have 14 ga wiring to them such as that alt-starter relay one; others are 16 or 18 ga

id the alt-starter relay Link is green then ck this site out for color codes, Link color/wire gauge

& swapping to Bosch or Ford relay such as in later model yrs is a vg idea!

this is what Steve did (on a 75 Bronco, but sim.)

 

[ccool416]

Code 542... I looked for something obvious... hmmm Ford emblem is missing from front grill???That don't make sense....

Oh... here it is...

542 Fuel pump circuit failure

From http://fordfuelinjection.com/index.php?p=51

Sorry... just jerking around.

In your truck you have a single IN THE TANK fuel pump/module, and a fuel pressure regulator on the rail.

There is also a fuel pump relay on the left fender wheel well.

Do you have a haynes or chilton's manual? They give a good discription of testing with a fuel guage (if you have one of those)

As you said... you don't hear it when you turn on the key.

You need to make sure that you have power to the pump, and that it is well grounded. OFten bad grounds will cause your problem. If I am reading the wiring diagrams correctly the ground to the fuel pump is located on the left upper radiator support.

You may also want to check to make sure that your inertia switch didn't trip, it is under the dash on the driver's side. The red button needs to be pressed down within the housing.

This issue has been discussed before, and if you do not have a haynes, or chilton's let us know, I have seen others post scanned images of the wiring diagrams for the fuel pump circuit.

joe

Haven't got to the emblem yet, the wife rear ended another truck and I am still in the process of fixing her back up..I have checked power all the way to the inertia switch, next move is to the pump..will do this weekend and get back to you

 

[miesk5]

Haven't got to the emblem yet, the wife rear ended another truck and I am still in the process of fixing her back up..I have checked power all the way to the inertia switch, next move is to the pump..will do this weekend and get back to you

Ck the ground back @ pump & pump + & - GL!

Diagram of connector/wiring by Steve