Water in Fuel and then wouldn't start - Ford Powerstroke Diesel Forum
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Old 03-02-2010, 02:15 PM
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Water in Fuel and then wouldn't start

Bought a 2007 F250 6.0 Harley Edition 4x4 last summer with 59k miles on it from Spokane, WA. I'm in Atlanta, GA. It now has 70k miles. Seemed to not have the power my last truck had which was the exact same truck, 07 harley f250...just fewer miles...it got stolen so I replaced it. So I replaced the fuel filters, had the fuel system cleaned, and flushed the tranny and changed fluids and filters.

Last couple weeks I started getting the "water in fuel" message. Ran some diesel kleen and some lucas then I drained the water separator. Kept getting the msg. Took it in for loss of power, they found nothing. Talked to the tech about the WIF msg and he said it was a bad sensor.

So I took the rail pump cover off where the WIF sensor is located, removed the sensor and cleaned the rust corrosion off (looked bad but cleaned up pretty well). Also cleaned out a good amount of rust sediment inside the assemply behind where the cover goes as well. Also changed oil and filter. Reinstalled all and fired it up. Started up, ran and then cut out. Couldn't get it back started.

Pulled the filter in the engine bay....looked muddy brown. Also the lil plastic piece in the middle of that housing..the 2 screws holding it in were rusty as well as the spring. Took those out and cleaned as best as possible. Replaced and put a new filter in there. Also took off the rail pump cover again and blew out the fuel lines between the rail pump and the engine compartment filter with air. I did not however change the rail fuel filter. Still won't fire.

Had it towed to the dealer. They are telling me that it needs a new rail fuel pump...$550 parts and labor. I'm wondering if there's more to this... rust in tank, messed up injectors, etc. There is a ford msg about the tanks having liner separations...does that help me here or am I on the hook for it all? No warranty coverage for fuel tank and rail pump with the powerstroke 5yr/100k warranty! Also if I have to replace, should I upgrade to something better?

I don't want to spend money if it should be covered... But if I have to pay, I don't want to replace a pump and not fix the ultimate problem..(rusty tank). And if I replace a pump, should I go with a better pump? What would that be?

Thanks, for any and all help!!! Nikk
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