Started up my truck today and was letting it warm up for a couple minutes when I noticed smoke coming from under the hood. I immediately shut it down and popped the hood the see this connector smoking and melting. What would cause this to happen? And what is the proper fix?
Truck is an 88 f250 7.3 idi.

 

looks like the fuel heater shorted out. There should be a fuel heater fix thread here somewhere. Search and you will find information on how to fix.

 

The fuel heater is not needed with modern fuel. Just leave it unplugged. There is a thread or three about the heater leaking fuel and the fix is to remove it, discard, tap the hole, and install a pipe plug.

 

Thanks bashby! Just the answer I was looking for. So I have to remove it to plug the hole?

 

Yes, but that's if it's leaking. Since it's not leaking don't worry about it.

 

Ya it's leaking pretty good out of that plug hole. It gets to -30 sometimes where I live so should I just put in a new o ring and connector? How important is this fuel heater thing?

 

It's leaking? It looks dry in the picture.

Most say it's not important and probably are correct. However I don't like disconnected/not functioning systems in my vehicles so I try to keep everything working when feasible.

Like Bashby said you can remove it, tap some threads, (1/2" NPT), and put a pipe plug in it. Check the FAQ for write up and pics.

 

Here it is, this tread contains the proper repair & the tap and plug option:

https://www.ford-trucks.com/forums/8...ns-w-pics.html

 

Thanks guys I'll probably try to keep it working and just fix it.

 

^^^^ +1; I don't see a leak. If they use winter blend fuel where you live, and as a "bent-and-suspenders" measure you throw in some anti-gel additive like Power Service white bottle, you should be fine without that heater.

 

My truck came with a water separator from who knows what installed (filter is for a Detroit). No heater on it, and haven't had any issues starting in the winter.

Just make sure to drain it regularly, I got lazy and we just dropped from 50 degree days to 18 degree days over the weekend, and today I had a block of ice in my separator that wouldn't let fuel past. Had to run a space heater out to the truck so I could drain it, since my heat gun is across town in my storage. Got it all worked out though.

 

it's not to help aid in starting the engine.it's simply there to help prevent gelling of the fuel in the filter.
i would plug it and if i needed a filter heater i would install thermal wrap around the coolant filter (an addition.not oem) and fuel filter to bundle them up,or install a universal blanket style heater wrap.

http://www.ebay.com/itm/like/181302587111?lpid=82

and i would use a devoted circuit for it if you have an E40D trans.when that oem line trips the fuse,it's on with a necessary fuse used for the transmission.the main power supply to the trans.the 20A fuse U.
for E40D trans,this line should be capped off and a devoted fused and relay setup to power your fuel heating element (if needed/desired) to avoid loosing your gears.
http://cimg6.ibsrv.net/gimg/www.ford...0eb322a2ed.jpg


when i got log truck,i had a leaking heating element at the plug like that,and it was smoking.it wasn't enough to blow thew fuse.rather i suspected it hurt the trans control unit over time and that's why i had to replace it.
very poor wiring on fords part.fine and dandy when brand new.get some age on the trucks though,and these will be the results.easily corrected with a little time.very easy for me,as i just eliminated the wire ran to the heater and plugged it.it's not a cold weather truck anyway (long wheelbases 2wd.)
it's been unplugged on chip truck for years as well.