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Discussion Starter #1
Hey everyone i need some help please. My 2008 F450 6.4 won't start. Wednesday i was driving on the highway went to get off and truck died. water in fuel light came on. It started back up and made it to the gas station put some fuel in it and drained the separator, not much water came out. Started back up running a little rough then cleared up. Started heading home cause every time i have a problem with this truck it's bad. Went to get off the highway truck died has not started since. Towed it home has code p2291. Changed both fuel filters (ford). Tried starting it and bleeding it for an hour still nothing. Water in fuel light on again, drained separator no water. Took the HCFM apart cleaned it out put new gaskets in it. Spent another hour trying to start and bleed it still no joy, again it set code P2291. LPFP was Showing 8psi on my gauge. Fuel rail pressure is 0.52 volts KOEO and occasionally go to 1.2 volts while cranking, would show about 70psi KOEO oand 650psi cranking.

So I figured the HPFP is bad. So I replaced it (there was no metal in filters or any lines). Put all new seals on fuel lines and replaced the fuel lines to the rails. Also replaced the HPFP cover gasket with the wires in it. Get it all back together and still won't run.

The old pump when i took it off was binding up could barely turn it, the new one spun freely.

Still setting the P2291 code. I have double checked the oil it has stayed at the same level. So i don't believe it is an injector or line leaking under the valve cover. I took off the engine mounted fuel filter and it seemed like a lot of air was coming in with the fuel. so i double checked all my lines could not find a leak. Thought maybe the LPFP was cavitating and causing air bubbles so i put a new one in. fuel pressure now reading 11psi on my gauge. Fuel rail pressure did go up to 1200psi one time that i saw but mostly stays about 750psi when cranking.

Why don't I have enough pressure? I decided to try to test the injectors again. Buzz Test showed no fault. Made a little tool out of one of the old fuel lines and used shop air to pressurize the rails and injectors, no leaks were found.

Put it all back together again. Have spent at least 6 hours trying to bleed out any air. I have had no luck.

Is the new HPFP bad? I did Test the PCV and VCV with an ohm meter and both were at 3.5 ohms.

I am really starting to dislike this truck, but I love it when it runs. Some repair history. Replaced all rocker arms shafts and pushrods 30k miles ago replaced right side lifters and pushrods 20k miles ago. replaced injector #2 10k miles ago and injector #3 1k miles after that. Truck Currently has 260k miles.All parts i have replaced have been genuine Ford.

Sorry for the long post trying to give you as much info as possible (and it's helping vent my frustrations). I am thinking that the HPFP is not any good but Ford does not want to believe that. If you have any ideas I would greatly appreciate any and all help.
 

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Is your low side still aerated? Are you sure you have no injectors bleeding off rail pressure at all?
 

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Discussion Starter #3
If I bleed the air out till I see no more bubbles, after I try to start it it will have more air again. I will try to pressurize the injectors again. I don't know where the air is coming from.
 

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Well i spent some more time and removed all of the glow plugs. Pressurized the injectors and found no leaks, also removed the fuel filter cap to see if there were any air bubbles. So i guess I am removing the high pressure pump again.
 

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Discussion Starter #5
I have not gotten back to the truck yet. I really needed to get back to work so I "rented" a truck from a buddy of mine. As soon as i get this back on the road i will keep you all updated.
 

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Discussion Starter #6
Success! After installing another high pressure pump it tried to start. Bled some more air out and it started but was running really rough and fuel was running out the exhaust. So I removed all the injectors and had them tested. 3 were bad and a couple were not atomizing the fuel very well. So I figured the pump must have trashed the injectors. So I just replaced them all. I also pulled the tank and cleaned it out and replaced the fuel filters again. Fired right up ran great smoked for a while burning all the fuel out of the exhaust.
 

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I replaced my injectors and lines, rockers and lifters, head gaskets, turbos and all of the washers on the fuel lines. Could not get air out of the system, truck would run for 5 seconds or so after bleeding it the would run out of fuel. Full of air in the system again. Did this for days! So I replaced the high pressure fuel pump with the same result. I bought the bleeding tool for the high pressure side. When I have that on the truck will run with air coming out steady. I ran 10 gallons of fuel through the bleeder which took about 13 minutes of run time! I did this a couple of times. Sounds like I might have a faulty pump? Code p2291. Also replaced gasket with wiring harness for hpfp. I'm getting pretty good at taking the turbos off now! Any advice would be great! Don't know what else to do!
Jacob
 
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