Early '03 with very Erratic fuel pressure showing on new dashboss - Ford Powerstroke Diesel Forum
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Old 06-02-2013, 04:41 PM
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Early '03 with very Erratic fuel pressure showing on new dashboss

This is my first post here, and I'm hoping some of you folks will help me. I have an early '03 Ex, with a late 2002 built 6.0. Milage is just 100,000. I've had it for several years and try to keep it very well maintained. A few weeks ago it started running really rough, and was really weak. I ran it on a couple of short errands over the next week and it seemed fine. Then it started acting up again, only worse. It would start but barely run. For whatever reason, I decided to try changing the fuel filters, even though they only had 7000 miles on them. I'm glad that I did, they were filthy, and much dirtier than I had ever seen them. I did, and always do use motorcraft filters, by the way. After replacing the filters it wouldn't start at all. The batteries seemed a bit low (maybe from sitting a couple of weeks), so I charged them overnight and tried again to no avail. I had hooked up my new Dashboss only a few weeks before, but really couldn't see anything wrong (OK, I'm a bit of a newby) and it was not throwing any codes. Since then I did the blue spring mod (what the heck, I'm messing around under there anyway) and hooked up the fuel pressure sender which I bought through Dashboss. In the process of doing all of this I discovered that one of the problems was that my batteries would no longer even take a charge, so I changed them (850 CCA batteries from Costco) After all of this, it's finally running great... So what's the problem??? (Sorry, I'm long winded) My fuel pressure is reading anywhere from 63 PSI on the high side to (get this!) -4 PSI! (Yes, I meant to write negative there) If I drive it down the road on flat, accelerating fairly normally, it shows anywhere from 45 to 62. If I get on it, or accelerate hard up a hill it reads as low as -4. The kicker is, it's actually running pretty nice, and especially with the new blue spring mod. It can hit this -4 reading going up hill under heavy acceleration without a hickup. Could I have a bad sender unit? I am totally mistified.

Additional information: my 5 volt source for power to the fuel pressure sensor is the brown/white tracer wire on the EGR plug. I programmed the
sensor in the dashboss as follows;
Low limit volts 0.500
Low limit value (PSI) 5.000
High limit volts 4.500
High limit value (PSI) 100.000

Thanks to anyone who will read this and take a shot at it. Mike
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Old 06-02-2013, 05:39 PM
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By the way, I just checked my "5 Volt source" described above, and it fluctuates between 5.02 and 5.03 volts with the engine running, either at idle or revving it.
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