I have an 06 powerstroke and the hcfm fuel pump went out. Installed new fuel pump, cleaned housing out thoroughly, and replaced fuel filters. After installing the hcfm back on truck I left the secondary fuel filter out and was going to install it after I saw fuel had made its way back to the engine. But no matter how many key cycles all I hear is gargling of what sounds like air and diesel never comes. I hear the new fuel pump running, can feel it, but it seems diesel never pumps? Is there some priming that needs to be done that I'm unaware of? Any ideas would be greatly appreciated in resolving this issue.

 

Usually takes me 5-6 times of putting the truck to ON position, wait until I hear the pump stops running then repeat until my fuel pressure gauge has stabilized and indicating 65psi.
But that's with the engine fuel filter completely installed.

 

That's what I typically do after installing new fuel filters or draining fuel when getting water in the fuel light. Being I don't have a fuel pressure sensor hooked up with having everything out I just left the secondary fuel filter out and was going to wait until I saw fuel in the bowl, install the filter, do another key cycle or two and start the truck. I cycled key literally a dozen times and each time waited until the fuel pump stopped humming and yet no fuel ever made its way to the secondary filter bowl.

 

Gotcha! that's interesting.
The In and Out are in the correct place?
The ports look very similar and can easily be reversed. Not sure if you disconnected them though.
Not trying to question your mechanical skills, just doing some process of elimination.
Check filter if installed correctly too.

 

It's all correct as fuel into hcfm from the tank is a different size than the return, the same thing on the other side when to secondary filter is larger than return from the engine and filters are always ford Motorcraft filters. It dawned on me with my previous reply that leaving the secondary filter out my just keep pump sucking air or preventing a draw given the fuel system is not primed so I installed the secondary fuel filter into housing and did 6 full key cycles then removed the secondary fuel filter to see if any fuel was in the bowl. Not a drop of fuel had made its way to the secondary fuel filter after 6 key cycles?

 

Is the fuel pump OEM or not? Could the polarity be somehow reversed?

 

Not OEM, I'm starting to think despite hearing the pump operate it's not functioning properly?

 

It could be you have a tank problem and never had a HFCM problem. More than 1/4 tank? The pick foot can lose its anti-icing valve and suck air at 1/4, the same if the foot has broken up due to age. Put a 3/8” hose on the inlet of the HFCM and the other end into a can of diesel and see if it pulls up diesel to confirm the tank vs HFCM debate.

 

You can hear it, so it's gotta be functioning. I'm curious about the polarity now. Pumps are just DC motors, you can make them turn clockwise or counterclockwise.
If there's no fuel at the HFCM, then the pump might be reversed is my guess.

 

I don't see how the pump wiring can be installed wrong unless the original plug was removed and then re-installed. You can't connect it up backwards without having modified something.

You REALLY need to tell us what the fuel level is (as asked in post #8).

You also need to make sure the primary filter O-ring is in good shape and the WIF drain plug isn't leaking.

I REALLY like the RACOR fuel pumps, and not a fan of going aftermarket for them. That said, I have not seen very many (if any) posts regarding problems with the aftermarket fuel pumps.

 

Thanks, TooManyToys...it's always the little and simple things that we sometimes overlook. Did as you instructed and the fuel pump doesn't lift any diesel from the fuel can.

 

You could try wet priming the filter and pump, using the hose lifted above and filling with something like a turkey baster, never to be used in the kitchen again. I’ve got one of those.

This is a rare situation and I would suggest as Mark noted, check the filter cap o-ring.

 

Thanks for the suggestion and I'll keep it in mind for the next pump. I returned that cheap one and ordered a quality one as I should have from the beginning. I'll update the thread once it arrives and I get it installed.

 

Please state the brands you are getting, as that detail can help others in the future when they read the thread.

 

The new Racor fuel pump arrived yesterday and I got around to installing it this morning. After four key cycles, I still was only getting air out of the secondary filter housing and didn't want to crawl back under the truck so I opted to fill the secondary filter with diesel. I filled the secondary filter housing up to the threads, cycled the key, and the diesel was sucked down. Did that 3 times and then installed the filter and cap back on the housing and did another key cycle and started the truck. Took a little longer than "normal" to start and the truck wasn't happy as it still had plenty of air in the system. Turn the truck off and removed the secondary filter again and topped off the housing with diesel. This time after it started to drain I turned the key on for a brief moment to fill the filter housing back up and after a few of those it was apparent the system was primed and the fuel pump operating normal again. Reinstalled the filter and cap on the secondary housing and the truck started right up. I let it idle for 15-20 minutes while I cleaned up my mess and everything was smooth. Thanks for everyone's help!