I have a 2003 f-350 with the 6.0. Just recently purchased this truck, and when I changed the fuel filter, I cracked the fuel filter cap. Truck ran for a while, then lost power. I checked under the hood, and saw fuel coming from the top of the cap. I purchased a new cap, installed it, and the truck won't start at all. It acts as though it is trying to, but won't fire. Any ideas would be greatly appreciated!

 

Are you using Motorcraft fuel filters? Did you replace the filter o-ring and oil it well before you put it in?

A common problem here is either not replacing or not oiling the lower filter o-ring properly, allowing the o-ring to tear or get damaged, allowing air into the system causing the upper filter bowl to not fill properly.

 

Did not use motorcraft filters, used hastings brand. I oiled the bottom o-ring before I installed the filter. The problem was the top fuel filter cap was cracked, with fuel seeping out. I just installed new batteries too, and it acts like it wants to start, but just never catches. Guess I should go get motorcraft filters, and start there??

 

That would be my advise. Make sure you oil up the new o-ring well, especially the lower one. You might also run your finger around the inside of the housing where the o-ring sits and make sure it is smooth. Also make sure the caps are tightened all the way, so that they're fully seated into the housings.

 

you ran it out of fuel you will need to crank on it for a little bit to get the air out.

 

And always use OEM filters and lube the O rings with oil, not diesel fuel.

 

+1^^^^^^^^^^^

 

Put new filters in, and still no start. I can hear what sounds like a very small air leak around the top housing, so I sprayed around it with soap water, and no bubbles, but every time I turn the key on, I can hear a slight air/bubbly sound. On the other note, I have cranked this thing quite a bit, I'm sure it should have purged out the air by now...

 

You should probably put it on a charger first off. If there is air in the fuel lines going to the head it could take awhile to purge it out, and you don't want to be cranking it with low batteries.

Then, turn the key to run and listen for the fuel pump. It's in the same module that has the lower fuel filter. Let it run until it turns off, then turn the key off, back on and do it again. Do this about 8 to 10 times. That should purge all of the air out of the upper filter. Then it's a matter of cranking it until it purges the air out of the lines from the upper filter to the injectors.

Another thing you can do as a test is to take the cap off of the upper fuel filter, remove the filter and have someone turn the key to run. Be prepared to have them shut it off quickly, as the fuel bowl should fill up pretty fast. If it doesn't, something else is wrong.

If you do this test, be sure to purge the air as I described in the first paragraph before you start cranking it.

 

Did all that, still no start. How long should it take to purge the air to the heads? Have cranked on it for quite some time, and even with a charger hooked to it, seems the batteries are still getting low, so I hooked up jumper cables to my other pickup.... There isn't some kind of fuel shutoff that might have tripped when it sucked a bunch of air??? As I am cranking, I am watching the exhaust, and no smoke at all coming out, which tells me no fuel getting in at all...

 

its probally your HPOP when they go out the truck will turn over but no start and it can happen at any time. You could be sitting at a gas station and turn the truck off and get in to start it and it goes out. Have a mechanic check that out bet thats what it is. HPOP (high pressure oil pump)

 

okay, I was wrong, when being cranked, it puts out little bit of white smoke, as it maybe is getting a bit of fuel. I can still hear what seems to be a small air leak somewhere below the top filter housing, but can't seem to locate it. Is this sound normal when the fuel pump is on?

 

its getting fuel but doubt there is an air leak it is probally the intake that you are hearing. The best way to tell if its getting fuel is to remove the small fuel filter up top and turn the key to on and see if fuel comes out if fuel comes out then im 99.9% sure that the hpop went out

 

Wouldn't that show up on my scanner?? And, on a side note, I put just a very small squirt of ether to it, after making sure the glow plugs were not on, and it started right up, ran for 3 or 4 seconds, then died again. Should I check the IPC and IPR sensors first, before spending bucks on a HPOP???

 

This is a good test, but if you do try it, make sure you do not crank the engine, just KOEO. You can pull the FICM relay to make sure it doesn't crank.

Also, there is no way to say that it is a 99.9% certainty to be an HPOP issue if it is getting fuel. These engines are far more complicated than that.