Fuel pump question - Ford Powerstroke Diesel Forum
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post #1 of 15 Old 12-10-2019, 07:53 PM Thread Starter
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Fuel pump question

Hello everyone. I have some questions about a fuel issue Iím having with my 2004 f250 6.0. Iíve done some research and have conducted a few tests to try and pin point the problem. Yesterday I was driving down the freeway, and it started running extremely rough. I pulled to the shoulder and it died immediately. Tried to start it and it fired up, but acted as if it was running on only a couple cylinders so I shut it down and called for a tow truck. When i got it home, i noticed the fuel pressure gauge on top of my engine mounted fuel filter cap reads zero. This is when I started researching. Both fuel filters are new, with maybe 1500 miles on them both so they shouldnít be clogged. Iím going to replace them again just for good measure. After researching I started my testing at the inertia switch which tested good. I have power there. I also have power at the frame rail mounted fuel pump, and I can hear it making noice when I key on the ignition. I unbolted the bed and slid it back enough to access what I thought was an in the tank fuel pump, which turned out to be the fuel pick up tube and fuel level sensor. The fuel pick up screen in the fuel tank is clean with zero crud in it. I was told by the ford parts department guy and the oíReillys auto parts guy on the phone that my truck has two fuel pumps. One in the tank and a frame rail mounted fuel pump. Well I am positive that I do not have a fuel pump in the fuel tank, so they were wrong. I have a sct livewire where I monitor all the important things to look after and my high pressure oil pump was working as it should up to the very moment all this started, and Iím confident itís not a possibility of the cause of what ever it is thatís going on. It did throw a couple codes. P0284, P0266, and P2290 which I think is the icp sensor going bad because icp actual is within spec. So is there another fuel pump that I am unaware of besides the frame rail mounted fuel pump under the driver side cab? I run a sinister diesel adjustable fuel pressure regulator, and have always had the fuel pressure running between 55-60 psi. The fuel pressure regulator did not back out and cause a fuel pressure drop. I pulled the engine mounted fuel filter cap off and pulled the filter out and had my wife turn the ignition on and the filter bowl will not fill up with fuel. Are there any other tests I should do before I buy a new frame rail mounted fuel pump for 400 to 600 Benjamins? Any information from the PSD pros would be greatly appreciated.


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post #2 of 15 Old 12-10-2019, 08:09 PM
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only one fuel pump

and it does shut off after a few seconds if you key on bu do not start the truck so checking fuel psi needs to be quick or with the motor running

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post #3 of 15 Old 12-10-2019, 08:11 PM
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ps the inertia switch kills fuel pump power so if you hear your pump run then don't suspect that device

i am a little suspect of the sinister part I would make sure that regulator did not fail

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post #4 of 15 Old 12-10-2019, 08:20 PM Thread Starter
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Quote:
Originally Posted by ZMANN View Post
only one fuel pump



and it does shut off after a few seconds if you key on bu do not start the truck so checking fuel psi needs to be quick or with the motor running


Before this issue started, my fuel pressure gauge would read 55-60 psi before the motor would start. Now it reads zero. I donít want to try to start the engine in fear of destroying my injectors.


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post #5 of 15 Old 12-10-2019, 08:28 PM Thread Starter
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Quote:
Originally Posted by ZMANN View Post
ps the inertia switch kills fuel pump power so if you hear your pump run then don't suspect that device

i am a little suspect of the sinister part I would make sure that regulator did not fail


I thought that would get mentioned, so to rule it out I put my old blue spring kit back on and still the same issue. The fuel pressure gauge needle will just barely come off of the stopper pin. I really think the fuel pump is toast, but really donít want to go throwing parts at it until I finally find the part that fixes the issue. Thatís how the repair shops get you.


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post #6 of 15 Old 12-10-2019, 08:53 PM
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and you can buy just the110.00 motor for the pump but if your pump runs but underperforms it may be time for the whole new HFCM

and your smart to not run it with low/ no psi

just make sure when you do check that guage the pump is running still after key on

and verify all your lines are clear and your tank has fuel ( I have to say that part lol)

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post #7 of 15 Old 12-10-2019, 08:57 PM
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Only Fuel pump is in the HFCM on the frame under driver's seat. The fuel pump is replaceable without changing the complete module but I recommend full replacement if it's never been done.

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post #8 of 15 Old 12-10-2019, 09:21 PM
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Nevermind, glanced over the post as it was just a block of words to me.
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post #9 of 15 Old 12-10-2019, 09:33 PM
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I would disconnect the outlet on the HFCM and put a hose on it and then into a fuel can. Turn the key on and see if you have high pressure fuel coming out of the pump. To me if he can hear what he thinks is the pump running but he is getting 0 pressure on the gauge this would confirm if his fuel pump is functioning properly. I always try the simple things first.

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Last edited by BTL; 12-10-2019 at 09:40 PM.
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post #10 of 15 Old 12-11-2019, 01:55 AM
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I just went through this. I could hear my pump run, but "I ran out of fuel".
I went through EVERYTHING. even pressurizing the fuel lines between the hfcm and tank. I just wanted to make sure if I was replacing the pump for a reason.
Even though the pump "ran" it was not pumping anymore. Not picking up, to be exact.
This is easier to diagnose than what I did. Simply disconnect the upper pump to tank return line and pressurize it, you should get fuel from the barb that line came off of, if not, there is your problem (something in the tank). If you do get fuel, your hfcm is now full of fuel, pop the lower fuel line off, turn on the truck, if you get a constant flow of fuel (not just a quart or so) the pump or hfcm, or both, is the problem. If you get a good flow from the pump, then the problem is in your fuel lines.


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