Excursion Diesel Stalling After Filter Change

I'm having a head-scratcher with my 2004 Ford Excursion diesel. It's got about 184547 km on the clock. Recently, the check engine light illuminated, and now the engine occasionally stalls when idling, especially after it's warmed up. I've also noticed a general reduction in engine power, like it's struggling to breathe. I recently swapped out the fuel filter, and I'm wondering if I messed something up during the process. Could it be a faulty fuel pressure regulator? Any ideas where to start looking? I'm thinking maybe an error entry during the fuel filter change might have triggered this. It feels like my fuel system is playing whack-a-mole with me!

4 comment(s)

I had a similar issue with my Excursion. It sounds like a potential problem with the pressure sensor after the filter change. Have you checked the fuel pressure? A bad sensor can cause rough idle and reduced fuel efficiency, much like a clogged artery restricting blood flow.

Thanks for the quick reply! When you say pressure sensor, are you referring to the fuel pressure regulator itself, or is there another sensor I should be looking for? And how exactly did you go about checking the fuel pressure? I don't have a ton of specialized tools, but I'm willing to give it a shot if it's something I can do at home.

Yes, I meant the fuel pressure regulator. While you might be able to diagnose it yourself with some tools, I would strongly suggest you consult with a workshop. Confirming the issue definitively will require professional equipment. I ended up having to get mine replaced.

Appreciate the advice. I took it to the workshop, and you were spot on – it was the fuel pressure regulator! They said it was likely related to the filter change, just like I suspected. 45€ later and it's running like a champ again. Thanks for pointing me in the right direction!

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