I've got a 89 F350. Last week it started that it wouldn't shut off with the key. That lasted for about a week until 3 days ago. The Fuel filter light would come on and I'd lose power and ultimately stall. After a few minutes it'd start. It did it two more times and then stalled for good. I replaced the mechanical pump (lift pump/supply pump whatever) On the passengers side of the block. It has GREAT fuel pressure coming out of the pump, before and after the fuel filter up to the injector pump. I have a decent pulse coming out of the injector lines. I replaced the injector pump, bled the lines, and it fired up. I got 1 mile down the road and the filter light came on, it stalled, and now won't start. It's a new filter so I drained it, refilled it, and screwed it back on. I put power to the solenoid and I hear and feel it click (fuel shut off solenoid). It also clicks with the key. After I put the new injector pump in it would start and stop with the key fine. So why won't this POS start or run?
The fuel filter light comes on to tell you that there is Water In The Fuel tank at a level high enough to be picked up by the fuel pump. Your problem is a fuel delivery system that is full of water. Drop the tank and clean it out first. There is a very specific procedure for replenishing the fuel system with good fuel. The best thing to do is pick up a copy of Haynes Diesel Engine Repair Manual, Part #10330 as it outlines the procedure. However, if you are unable to get the book reply in the comment section and I can type it out for you. It requires 14 steps.
While you are doing this it would be a good idea to also replace any and all rubber pieces of fuel line. They have been known to collapse over time, when the pump comes on. Make sure you get fuel line that is diesel specific, regular gas line won't work. You mentioned replacing the injector pump so it will need to be taken to a diesel shop to be re-timed. Timing involves tools that are expensive and not normally accessable bu you and I.
The Hanes manual is an excellent investment at about $22. It provides excellent repair procedures for your engine as well as some service up-dates and shortcuts.
Testimonial: "There is a separate light for water in the fuel it says "water in fuel". The fuel filter light indicates that there is a pressure variable it the filter. Example: High fuel pressure in the filter indicates a clogged filter. Low pressure indicates possibly air. The injection pump is gear driven off the timing gears. It was set and installed correctly. However, I am leaning towards a bad selector solenoid (front or rear tank) shutting down the fuel supply. I will be installing it tomorrow and will update if there are no useful solutions."
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