Okay. Help.
I have a 2007 XLT supercrew 5.4L.
To date I have replaced the FPDM, fuel pressure sensor, injectors, plugs, and coils, and have cleaned the MAS.
Truck has no power above 3000rpm, and can barely tow a pop-up camper. When accelerating like going to pass a car, truck bogs down, and stutters. I get pending codes p2004, p0193, p0325. I am ready to buy a chevy.

 

Have you had the cats checked?

 

That does sound like plugged cats. However, your codes point to a stuck IMRC/CMCV and problems with the fuel rail pressure sensor and knock sensor circuits.

 

I changed the fuel pressure sensor with no change in the code. Would the catalytic converters cause the surging and stumbling? I was thinking fuel pump, but was a shot in the dark. The engine will rev fine with no load. Would a throttle position sensor cause anything like this?

 

You can get the throttle position sensor code when it is fact a dirty throttle body. Happened to me at about 95,000 miles on my 2005. Cleaned the throttle body and all was fixed. It was sending me into the fail safe mode.

 

If you changed the FRPS and the code came back, the new sensor is bad or something is wrong with the wiring.

 

Heh, no. But, if the engine was running so poorly that the raw fuel melted down the cats, then that is an issue.

I don't know (nor do others, I bet) your diagnostic methods, though.

P2004 is for the IMRC system
https://www.f150online.com/forums/20...odes-help.html

P0325 is for knock sensor circuit
http://www.ford-trucks.com/forums/70...k-sensors.html

P0193 is for Fuel Rail Pressure Sensor Circuit High Input
http://repairpal.com/obd-ii-code-P0193

 

IMRC, knock, and fuel pressure all go through the back of the harness on the firewall. You could have a damaged harness. Did someone have the intake manifold off the truck?

 

Don't know. I bought the truck two months ago. If I clear the codes after I start the truck, they will show as pending but it won't light the check engine light unless I shut it off and restart.

 

The engine starts and runs fine during normal driving. The stumble and lack of power only show up when the engine is under a heavier load such as towing or heavy acceleration when it gets to a higher rpm. When the pedal is on the floor, it will pull hard to about 70mph then fall on its face just before an upshift at 4700 rpm and starts surging like it runs out of fuel.

 

I checked the IMRC linkage when I had the fuel rail out and both sides were good. If the IMRC actuator is bad will it only throw a code for one side?

 

It takes two key cycles for circuit malfunction to show up on OBD2, thus the pending code on the first time you run it

 

Update.
Wires check good between PCM and pressure sensor. At this time, p2004 code has not returned. Ford tech may get a call tomorrow to hook up on computer. $85.

 

Had a thought and pulled the fuse for the fuel pump, turned on the key and got the code to come back without the pump running. How often do people get bad new fuel pressure sensors? So I picked up ANOTHER new sensor and...still get the code. I think I know why the previous owner traded it in.