I had the fuel pump changed. The new pump went bad after a few days, delivering only 20 psi. I got that number from FORscan. There is no scharader valve on my stock fuel rail. A new pump was put in. Pressure now reads 38-41 psi. Runs fine, no power loss. After a few days, one of the upper orings on a fuel injector bulges out and fuel starts to spray. I changed that oring. The same thing happens again and again, across different injectors, but only on bank 1. Always during cool down, in my garage.

I noticed that the injectors on bank 1 had more vertical play than those on bank 2. How do I fix that? I got a BBK fuel rail, and 8 new OEM injectors (parts cannon), and that was a waste of money, big fail, after-market parts are junk, but I have 8 new injectors.I see three more options: modify the intake bolt towers, modify the OEM fuel rail, or add fuel injector retaining clips.Ford has them as a part for this car, although they did not come with them from the factory. Tried the clips, but that put the injector too far from the intake with the fuel rail as it was, IMO. Also, it’s a bad design; it holds the injector to the fuel rail at only one point of contact, which will not hold, again IMO. So I modified the fuel rail. Now there is no vertical play with the injectors. Ran fine for a few days. One day I started the car up, and the oring bulged out, spraying fuel. I checked and found vertical play in the injectors, but the same as bank 2 has.

Maybe I'm focusing on the wrong parts?

Using FORscan, the "Fuel Rail Pressure" shows 51.9 psi (3.47V) at startup and 40 psi (2.80V) while running at idle. I saw 55lb at WOT. All this with the vacuum connected or disconnected (it jumps a little but settles down after a second or two). There should be some difference, but since I'm reading it on FORscan, should there be? A post from Eagle2000GT makes me think it's normal.

Could the fuel rail pressure monitor (FRPM) be telling the fuel pump driver module (FPDM) to increase the voltage to the fuel pump (FP) too much? I don’t see anything in FORscan to think that, but I don’t have it connected when the oring pops since it will not record in the key off position.

How much pressure can that oring hold back? Can a fuel pump make that much pressure?

I see that the "Fuel Pump" in Forscan is at 75% during startup and 17.xx at idle. "Fuel Pump Monitor" is 87.5-114%, but most of the time it's at 100%.

Can I power the FP with 14V constant power and wait for the oring to pop? If so, what would be the easiest way?

The ultimate question is, how do I keep the upper fuel injector orings where they belong?

 

I forgot to start that this is a stock 2003 mustang GT.

 

UPDATE:

I used the after market fuel injector retaining clips, they hold the injector at two points. So far they are working because after a few days the fuel pump became dislodged in the tank My guess is from the pressure, but not when the fuel pump is on but when it's off is my guess. I installed a digital fuel pressure gauge along with the stock fuel pressure sensor. While the car is cooling down, after a drive, the digital fuel pressure gauge increases > 100 psi. I never see that kind of pressure while driving. I would expect an increase from the heat soak, but should it be that high?

I also ordered a new OE fuel pressure sensor because it and my gauge differ by 2-12 psi

 

Glad things are working out for you. About 5 yrs ago I installed aftermarket fuel rails and better injectors and learned a valuable lesson: I hate working with parts that deal with gasoline...to this day, I still smell gas in and around my engine compartment.... Yup, I have no leaks....have checked and double checked many times..