Air in the fuel line - Ford Powerstroke Diesel Forum
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Old 03-06-2013, 11:00 AM
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Air in the fuel line

Proud owner of a 2003 7.3L F-250 I bought back in October.

However... truck died the other morning about a mile away from my house, pulled the filter and it was pretty dirty & seemed restricted, so I replaced it. Filled the fuel bowl 1/2 full, screwed the cap on, cycled the fuel pump 5 times, checked for leaks, found nothing, so I started it up. Motor ran for about 2-3 seconds and died. Turned it over a few more times and nothing.

Did some more research, pulled the filter again, removed the filter check valve just in case that was malfunctioning, and started filling the bowl to see how the incoming fuel looked. Lots of gurgling, then once the fuel level in the bowl passed the inlet port, just a ton of bubbles. It's definitely getting fuel along w/ the air, but lots of air.

Before I pull the tank and check for restrictions and possibly do that hutch mod, does anyone else know of any other things I should check that may account for all the air in the line?

Thanks.
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Old 03-11-2013, 06:37 PM
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How full was the tank?
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Old 03-12-2013, 12:02 AM
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Just below 1/4 tank.

I'm thinking it's the fuel pickup in the tank. Planning on doing the hutch mod.
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Old 03-12-2013, 02:54 AM
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These trucks are notorius for sucking air when they get below 1/4 tank. Definitely do the tank and fuel line mods if your is sucking air that bad.
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Old 03-12-2013, 04:29 AM
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I'd agree with that too.
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Old 03-12-2013, 08:56 AM
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Ordered the pre-pump kit from Strictly Diesel. Also replacing the fuel bowl seals (had a leak, pretty sure it's coming from the bowl drain lever). I'll post the results.
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Old 04-28-2013, 08:51 AM
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Realized I forgot to post my results from the Hutch mod...

Dropping the tank was a bit tedious, but got the mod installed. I used the kit from Strictly Diesel. Also did the harpoon mod.
Primed the new filter, cycled the fuel pump a few times, and boom: truck started fine, and has been running well ever since.
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