[bismic]

What are you using to check for codes?

Where is your ICP sensor located?

 

[bismic]

I was asking about the ICP to see if your 04 was an early one (with the 03 engine) or a later one. You have the later 04 engine.

Do you have a way to measure the fuel pressure?

At least remove the secondary fuel filter from the bowl, remove any standing fuel, then have someone turn the key on (do not crank) to see how fast the fuel bowl fills. Be sure to have the person on the key ready to quickly turn it off when the bowl is almost full. Post up how long it took to fill the bowl. And watch for bubbles as it fills.

 

[bismic]

Hopefully you haven't been installing aftermarket sensors and actuators. A percentage of those have been known to cause problems out of the box.

The air bubbles obviously need to be eliminated as your top priority.

Where did you buy the fuel pump? I assume it was just the pump and not the entire HFCM?

Bubbles can also come from the fuel pressure regulator. With all the parts installed, did you ever re-build that with the blue spring kit? It is important to install an OEM regulator kit.

Maybe it would narrow down the possibilities if you ran a hose from a bucket of diesel to the suction fitting of the HFCM and then see if that eliminated the bubbles when pumping.

 

[bismic]

I wasn't exactly sure what he meant by "bubbles with the key turned over".

 

[bismic]

If the pump is from Autozone it is NOT an OEM part.

Also, you are mixing words that makes it a bit hard for many of us to fully understand.

Replacing the "entire pump" for example........ you either replace the pump by itself, or you replace the entire HFCM. Saying you replaced the entire pump just doesn't clearly describe what you did. It may seem like nit-picking to you, but communication is all we have to go by in an on-line help forum.

Also, the key is turned on, or the key is turned to crank (that is where the engine "turns over"). I assume you mean that turning the key over is the same as turning it on, but it isn't common to see it described that way and it seems to be mixing terms.

I know it is all clear to you, but if it is a little cloudy to us, then it just gets in the way of us helping.

As I said - you don't know where the air is coming from. Running a sump wouldn't help the issue if it is at the regulator (o-rings) or the HFCM. Pumping through a hose (from a bucket) would quickly identify the "general" area of concern for the cost of a short section of hose and a hose clamp.

You can spend money guessing at things, or you can do some testing (essentially for free). Pretty much your two options.

 

[bismic]

Agreed!

Not getting all the questions answered, and AutoZone parts. Makes it hard.