i've got a 2003 XLT 6.0. On first start up in the morning, it will start then instantly die. it'll do this 2 more times then it will start and run normally. Fuel pressure is only around 25PSI idling. it sounds and drives completely normal once I get it started. New HFCM including new send unit installed this summer. Blue spring installed a month ago and made no difference. Both fuel filters were changed with the blue spring. No bubbles in secondary fuel filter bowl BUT it does not fill up well and the fuel retreats when I stop cycling the fuel filter. Im not sure where to begin with diagnosis. the fuel pump must be working or it wouldn't start and run at all. it might be running weak but I'm not sure how I'd verify that? I know I should drop the tank and check pick up, but Ive always tried to do the easier diagnosis first. I'd hate to go through all that effort and have it be something else simple. Anybody have any other ideas?

 

I suppose that FORScan found no codes? Whatever you decide to do, just remember low fuel pressure will cause damage to injectors and injectors are expensive.

For clarity, were you having the same issues PRIOR to installing the HFCM and sending unit?

Can you post where your parts were purchased (including the filters)?

IMO, the secondary fuel filter housing draining after the fuel pump stops pumping is typical, especially for the pre-2004 (late 2004) MY's.

If the fuel pick-up tube has broken (recently or in the past), you may have small debris clogging lines. That said, it seems unlikely that a newly installed pickup tube would fail so quickly. What did the old one look like when removed?

It sounds like you may be heading for dropping the tank. If you do so, I found it to be a good time to install a sump. Some people like sumps and some don't. For me, it made emptying the fuel from the tank very simple and also made a visual inspection of the pickup tube from the hole quite easy also. Who knows, if you do put a hole in for your sump you may find that the pickup tube/foot is fine. Then you can put off dropping the tank for another time, and look elsewhere for your issue.

 

Sorry for the delayed response. the pump was purchased at Napa, the filters were purchased at Advanced Auto. All my parts have always been purchased at Advanced Auto ( Ive got a long standing relationship with the employees and owner) and a local diesel shop. always OEM motocraft parts and materials.

the issue was not present prior to replacing the pump, nor after. pump went out this spring.(I had to replace it on the side of the highway using only my left hand. my right hand was broken. 0/10 DO NOT reccomend haha) everything ran fine till about 3 months ago.
If there is clogs in the fuel line, can I blow it with air? is there any check valves or anything I would damage?

The pickup isn't new, I've never replaced it. That's my suspicion at this point. its just odd to me that it is only on the first start up. the rest of the day it runs fine. the pressure continues to be low however.

 

From a recent thread on another forum - the NAPA secondary fuel filter doesn't seem to have the tab to align the air bleed hole. The web site does not list an OEM fuel filter option, but I see that Advance does - hopefully it is truly an OEM filter of OEM quality (there are just too many ways to cut corners and still advertise as OEM - eg buying second tier quality that could not pass a full set of quality specs).

Typically (but not always) the broken pickup tubes (usually the foot with the screen) happen to where the issue will make itself known at around 1/4 tank.

I would disconnect the fuel line at the HFCM and at the sending unit and then blow air through it. If your pickup tube "foot" hasn't broken yet, blowing air through it might cause it to fail.

 

There is no NAPA filters on my truck, currently or ever. The only filters that have ever touched my truck ( since I've owned it) are motocraft. current filters were purchased at Advance Auto.

Do you mean to remove the incoming fuel line from both ends? Not touching the return? If I were to do that, it would be completely disconnected from the truck, how would it damage the pick up line?

 

It wouldn't. That was the point of the advice to remove it from both ends.

The last sentence was just to communicate the reason for the sentence prior.

I re-read your post earlier and saw that you used Advance Auto for the filters. Even though they advertise them as OEM, still not my choice for sourcing OEM, I am a die-hard skeptic though. Good to know that they have seemed to be fine for you though.

 

What part of the country do you reside. Any chance you are gelled up? We're at -20F and my truck gelled up last night. Fuel pressure was all over the place.