Hi All been around the forums have been doing plenty of research. My van is a 2005 Ford E250 standard body 5.4l V8. 242k miles
I have been fighting this van of mine for dang near 8 months now. Background I bought it not running. Had to do timing chains, tensioners and did a high pressure oil pump. Worked great for over a year. Now on to the good part. I would randomly get lean codes for bank 1 & 2 but they would come and go. I also would have random instances where the van would lurch. Act like it would loose power then kick back up and keep going. It felt like a transmission slipping but it was not a transmission slipping. Couldn't pin point till one day they stuck. Bank 1 & 2 lean codes stuck. Using my scanner I watched STFT and LTFT and found at idle everything bounced right around 0 (+3/-2). Did a vacuum test on multiple different points have good vacuum, did a smoke machine test for leaks found none. Tested the exhaust at the front O2 sensors to check for clogged cats. Came back normal. Tested fuel pressure it was with in 1 or 2psi + or - of the desired PSI the computer was calling for. I found going down the highway the STFTs would run all the way up to +40 and just stay there. Fuel pressures held steady while running down the highway also. Right around the desired psi. I took that as a fuel issue as generally at highway speed and it leans out that would be a fuel delivery problem so I threw the kitchen sink at it. I replaced all plugs (motorcraft plugs), all coils (went with standard products coils because motorcraft is dang expensive), replaced all 8 fuel injectors (Bosch), replaced the fuel pressure sensor (standard products), replaced the fuel filter (WIX filter), Replaced air filter (Wix filter), Replaced the MAF sensor, replaced the fuel pump driver module (Standard products) and I also replaced the fuel pump. I replaced everything because I had been wanting to "refresh" everything under the hood etc. But anyway back on track. The van ran great for 1000 miles then lean codes came back 1 & 2 lean and they are back with a vengeance. But now I also got 2 more codes P0104 (Mass air flow/VAF circuit intermittent) and P061B (Internal control Module Torque Calculation Performance). Seems like a lot of codes for all the work I just did 1000 miles ago. so I dove deeper. Watched the scanner found the EVAP was running weak. Found a twisted EVAP line right behind the tank. Probably from when I replaced fuel pump. Straightened that out and that fixed that issue. The internal torque performance code was very odd to me but I have another econoline sitting around so figured I would throw the PCM from that one into my "good" van. Took 10 mins swapped them out and went for a drive *After getting the ignition programmed to the PCM. Within 50 miles all the same codes came back except the P016B code and a new code P0148 (Fuel Delivery Error) . P016B didn't come back but I also now can't even drive the van down the road. Using the scanner I found that fuel pressure is jumping from as low as 5 psi all the way up to 80 psi when driving. So remember what I said above about the lurching issue that was very random and sporadic. So now with the fuel pump jumping up and down like that the lurching has gotten so bad that I can't hardly drive it. Which makes no sense because basically everything is new on the fuel system. The issue started out slow and random when the codes first set but after doing all the work till now it has gotten steadily worse to the point I cant even take it down the road the issues gotten so back. I am at a loss. Any help would be greatly appreciated. If I missed anything or if anyone needs more clarification just ask please. Confused and will not take it to a shop anymore as I can generally fix anything else but this has me 100% stumped and slightly angry haha I did notice every time the lean codes would set and the check engine light would come on I could instantly feel the van loose power and turn into a dog had no guts of any kind.

 

You are in deeper than you realize.
this will require a shop with reprogramming capability,plus an understanding of what the various codes are SUGGESTING .

You can't just switch PCMs. That is a NO-NO. Doing that confuses the systems in the vehicle. and now neither PCM can work as it should. The vehicles are INDIVIDUALLY PROGRAMMED..
After that gets straightened out, what is used to see just what is going on is a scan tool that can provide graphing and recording functions to be examined AND an understanding of what affects what.
The problems you are facing require more than just replacing parts.
Can appreciate your predicament, but you are working with one hand tied behind your back.
You would be best served to have a capable shop tackle this right from the beginning.

 

You can just swap PCM's though... Everything is the same from van to van literally same part number from PCM to PCM is the same.. Only had to get the ignition programmed to start it. It is throwing zero codes for PCM errors or communication errors, the theft deterrent system is happy after the swap plus ignition key programming. I should of added that I got the keys programmed into it from my van. I know what is used to see what is going on as I have one. A snap on solus. That is my predicament is that I have watched the graphs and recordings and and ran any test any other shop would run. As I do work at one myself... Plus have had a few others look at it and ran the same tests that I have ran with finding nothing. But everything that I tried to do to fix the issues same result plus what others have done ended with the same result. Would run great whether its 50-1000 miles then right back to crap to the exact same issue. It has just now got to the point where it can't be driven. Yes its throwing those certain codes I posted above. Measures have been taken to repair those issues. aka fueling issues because of the leaning way out going hwy speeds. Vacuum leak tests have been done with no result of any leaks. Compression tests have been run to make sure everything is up to par there. Timing has been checked to make sure it is in time and it is in time. I came here because I am out of ideas of what else I can try. I should of added the other information about getting the ignition programmed in fair. I have had other shops look at it along with me. I have spent way to much on other shops for them to come back to the same conclusions as what I have already done. I came for more ideas not be told what I did wrong with a simple PCM swap. While yes you are correct if you just direct swap and nothing matched up aka part numbers, no ignition programming I absolutely agree that can throw stuff way off. So sorry for the miss understanding of what had been done/hadn't been done etc.

 

You should have Freeze Frame capability. What is your scan tool showing there?

I would expect you know what values are normal. Which ones appear abnormal?

Can you post the data stream info at idle and at 2500 RPM. Maybe you might be overlooking something and after we step into wanoona with both feet , we are not too proud to ask for a different possible point of view. We have all been there and some of us quite a bit lol.
What do you think ? Thanks.

 

That works for me. I will get it all this weekend and get it uploaded to here.

 

I apologize for not getting that information that was asked for. Got to busy and the van sat. But after taking time away I decided I'm tearing the harness out and here is what I found. Harness was laying across the EGR pipe and burned into 2 wires. The green and white wire controls coil #1 which caused the miss fire I was feeling because the coil was stuck on from grounding out. 2nd wire was the blue and red one which was the maf output wire which for obvious reasons sent the computer into a spiral of random bad information. Runs great again and I guess got a lots of new parts to run for a long time yet. Thank you guys for your help.

 

The problem you found is somewhat common to those years and models.
Thank you for the update.