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There are a couple of sensors in an electronic fuel injection system that can cause starting problems similiar to yours. But it does sound like a fuel pressure leak down situation, and that is where I would look first. By the way, has your vehicle "set" or "thrown" any trouble codes that might point in the right direction? Upon start up, does it run reasonably well or does it blow out any smoke for a moment or two?
Fuel injection systems operate under high fuel pressures. Your engine probably needs fuel pressure better than 30-35 psi to start and run. Compare that to the typical carburetor-fed engine that operates on anywhere from 5-8 psi. And diesels operate at incredibly high fuel pressures at the injectors. Usually the ECM (electronic control module or computer that monitors and runs all of the engine control systems) will not allow the engine to start until minimum fuel pressure is reached at the injectors.
Best way to check for a possible pressure loss is by attaching a fuel pressure guage to your fuel system....you should have an access port on the main fuel line in the engine compartment or on one of the fuel rails on your engine. (A good shop manual will help!) A reliable guage is not terribly expensive, and installation sounds more complicated than it is.
When you first turn the key on without starting the engine....the guage needle should jump almost immediately to 30-40 psi or higher. After turning the key off, the needle should STAY there for quite some time. If EITHER of these do not occur, you have a fuel pressure problem. Remember, these are closed, pressurized systems. Fuel pressure loss is usually caused by an internal leak inside the fuel pump (oftentimes the one-way fuel out valve) or by one or more leaking fuel injectors. A faulty fuel pump will NOT usually "throw" a trouble code....injectors sometimes can, but not always. Once the engine starts and adequate fuel pressure is maintained, the problem goes away....until next time. And remember, if it is a leaking fuel pump, a lot of the fuel in the lines eventually goes back into the tank. And that fuel has to again be pushed a long way and re-pressurized every time you crank the engine. That seems to be what's going on here. Leaking injectors can also cause pressure loss as stated, but that would usually also bring driveability issues as well, most pronounced upon start up.
A good, competent service facility that works on MH's can easily pull codes and check for proper fuel pressure readings. If all of this points to fuel pump leakdown, take a very deep breath and count to 20. Most new fuel pumps these days cost between $400 & $500. And labor goes on top of that! If they say "rebuilt pump", plan on re-visiting your problem sooner than you want.
One other note. A neighbor recently had a starting issue similiar to yours. His 20 year old Aerostar van would crank and crank and crank. Eventually it would start after cycling the key on/off many times. Had plenty of spark, and the throttle body injectors worked just fine. Fuel pressure would come and go....but pressure was immediate when the vehicle started, and it would stay after the key was turned off. The vehicle ran fine for several days until the problem came back. Strange. Turned out to be a worn out ignition switch...it was not always allowing power to be sent to the fuel pump circuit. Replacing the switch solved the problem. One just never knows sometimes!!
Sorry for the long post, but I hope this may be of help. PLEASE let us know how you resolve the problem....Thanks!!
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2003 Fleetwood Revolution DP
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