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Fuel pump is going, that's how the start to act up, does it stop running after it gets hot? They will tend to stop working when you are low on gas and the pump will get hot (the gas cools the pump) then after it sits for a little while the pump will cool down and the car will run finer until it gets hot again. This is typically what will happen to a bad fuel pump. Also make sure that the wires that go to the pump are energized when you turn on the key. You will hear a high pitched wizzing sound, that's your fuel pump spinning up to make pressure to the injectors. Check the fuel pump fuse and make sure it's pushed into the socket and making good contact.
Also you may need a fuel injector cleaning, this has to be done at a garage. Additives do not work! I had mine cleaned on my Mustang when I first bought it and what a difference it made, it would die as I shifted gears and several garages couldn't figure it out but the Ford dealer fixed it instantly for $70.
Maybe your injector circuit is not working. Pull off one injector connector and check for power on one of the two wires to the injector-turn key to on, and one wire should have power. If no power with key on, pull off all injector connectors and recheck for power- a shorted injector may shut down the injector circuit, that's why to pull off all injector connectors. If still no power on one wire to each injector, diagnose the injector drive circuit. Also check the fuse for injectors.
You have fuel runback.Replace the injector leak off pipes then try.If this does not work then have a non return valve fitted to your fuel supply pipe close as possible to the punp.Hope that was helpfull good luck.
Im assuming this is a 3.9 ltr 6cyl? any way there is always three things to check in regards engine not starting.
1. Compression 2. Spark 3. Fuel. "make sure you have fuel in the tank" first :)
If your vehicle is EFI
If you cannot smell fuel. Carry out these simple checks. When the ignition is on engine off, Do you hear the fuel pump prime. This is noticeable by a short buzzing noise in the rear of the vehicle and then it will stop,
If noise is not present check the fuel pump fuse, then the relay, and last of all the fuel pump.
If the fuel pump is operational. Make sure the fuel filter is not blocked and obstructing delivery of fuel to the injector. If the fuel filter is ok, remove the injector plug from a injector and using a led circuit tester, or a noid lite. check for injector pulse.
If there is no injector pulse then it would possibly be a ignition module http://www.injectacarb.com.au/ford-falcon-eaed-ignition-module-p-40.html if this model of vehicle still uses a distributor
This only because I dont know if your vehicle is 3.2 ltr, 3.9 ltr single point inj, or 3.9 multi point inj,
ps: To check for injector pulse, using a LED TEST light just connect the test light in between the 2 terminals off the injector plug, and check for flickering of the led, this will say that the injector is pulsing.
A noid lite basically justs fits into the injector plug .
I hope this helps, let me know if you need more help. Regards.
Although you say the fuel pump is working properly, you still need to ensure that there is actually fuel getting to the rail, and the easiest way to do this is to first of all clamp the fuel return line from the fuel pressure regulator so that the fuel flow back to the tank is restricted. Now try to start the engine. If it starts and runs, or starts and then cuts out after a few seconds, then you need a new fuel pressure regulator.
If the car still won't start then pop the fuel inlet pipe off the fuel rail, hold it in a glass jar or bottle, and then have someone switch on the ignition so the pump primes. You should get a good jet of fuel from the pipe. If not then you need to turn your attentions to the fuel filter and the fuel pump and its built in check valve.
Next you should use a volt meter or a 12v test lamp to check for battery voltage at the fuel injectors. each injector has 2 wires to it, and one of these wires should have battery voltage to it with the ignition switched on. If not then you need to check the injector harness connector for security and condition, and check that none of the wires in the injector harness are nipped or crimped anywhere, and repair as required.
If the voltage is there then you know that the problem is a lack of injector pulse, or too short an injector pulse, and as you have already replaced the ECM twice, I personally would double check the injector wiring and then fit a new camshaft sensor and see if that solves the problem.