PSD Gurus

[foreman1063]

I'll try to be brief but probably won't.

08 f-350, 170k, DPF/Cat EGR system delete, H&S Mini Max, recent head gasket replacement.

Last week: Changed both fuel filters, removed HFCM cover and cleaned out all the gel crap, replaced cover. Removed fuel pump wiring harness and soldered a new 'water in fuel' sensor connector on (lock on old connector broken), replaced harness.
Once I finished up I primed the fuel system several times and the truck fired right up. I let it idle for a few minutes then drove it to it's parking spot and shut it off.

Saturday: Got in, turned key, all dash lights lit up correctly, glow plugs cycled but no start, nothing! Cycled key a few times, still nothing. Checked DTC's on Mini max and came up with P0232 (fuel pump secondary circuit high). Cleared code several times and when it finally stayed clear the truck started. This went on for a couple of days and some times I had to reload the tunes on the Mini max in order for it to start. During all this one of the batteries died so I thought That may be the ultimate problem. Replaced battery, truck started right up several times, Problem fixed. Wrong!

Drove about 3 miles yesterday and the truck chugged a couple of times and shut down. This time got codes P0232 and P0192 (fuel rail pressure sensor circuit low input). reloaded stock tune and then back to H&S tune fired up and took off for home. Got a block from home and shut down again, cleared codes several times and was able to get home.

Now: I just picked up a new fuel pump harness to install and I'm going to take out the fuel filters I just installed and put in a new set.

Any other ideas based on these symptoms a DTC's?

Thanks

 

[foreman1063]

Figured it out

 

[Hurley]

well, GO ON MAN


(you've got my interest in the issue)

 

[Stuntman Autoworks]

Just seen this thread, so what was the fix?

 

[foreman1063]

I'm a little hesitant to admit this publicly but since you asked (What the hell, this thread isn't getting many looks anyway).

Two of the three connectors on the frame mounted fuel pump harness are nearly identical, in fact they will plug onto the wrong male end. I had the water sensor plug on the pump plug and vice versa. So, instead of the pump getting 12vdc, it was getting 5vdc. Just enough to let the pump run intermittently but not enough to supply reliable fuel pressure to HPFP. Doh!

Time for new glasses I suppose. ops:

I'm just glad I didn't tear into the HPFP or associated sensors/wiring.

Lesson well learned!