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Discussion Starter #1
Had a fuel leak on a 95 f250 7.3. Changed o-rings on fuel pump and filter canister. When I put it all back together it ran ragged. Any ideas? Injector issue, or not enough fuel pressure? Thanks.
 

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Had a fuel leak on a 95 f250 7.3. Changed o-rings on fuel pump and filter canister. When I put it all back together it ran ragged. Any ideas? Injector issue, or not enough fuel pressure? Thanks.
Check the harness that is on side of canister that has connector. This is the harness that leads to IPR. You might have oil in connector or cut wire. Wiggle that harness around while running and see what it does.
 

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Discussion Starter #3
update

Tried moving wire harness connection on side of canister while running, tried messing with all the wire connections, nothing helped. Currently it runs even worse than before.

I did find one more thing. The passenger side connection (part of which is for the glow plug?) going to the head, furthest in front of the engine, has a single melted pin (the pin closest to engine front), when I tried to clean it, it snapped off. Any idea what that pin is for, and if it would cause the rough running, and why it would melt in the first place? Replacement part numbers would be appreciated as well. Open to all ideas here. Thanks.
 

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On all the valvecover harness connections, the outermost pins are for the glowplugs (2 each connector). The middle 3 pins are for the injectors. If the glowplug wiring has melted or burned, it could have shorted with the injector wiring. I would bet that this may be the source of your problem. You can get harness repair kits or a simple pigtail for the external connectors. Internal harnesses under the valvecover are simply replaced. If either external or internal connections are melted/burned, replace the valvecover gasket as well! Sniff the oil cap for that butned electrical smell. Here's some part numbers:

Under Valve Cover Harness (94-97)
(Ford) F4TZ-9D930-K
(International) 1815923C92
(Napa) 700-2371

Valve Cover External Harness Repair Kits (contains 4 hard shells w/seals, w/o pins)
(Ford) F7TZ-14489-BA (94-96) w/o pins
(Ford) F7TZ-14489-AA (97) w/o pins
(International) 1830829C91 w/o pins
Female Pins, no wire lead (International) 1661875C1
Female Pins, with 6” wire lead (International) 2501055C1
Individual Wire/Pin seals (International) 1661872C1
Pigtail with 5 Wires and Connector (Performance Specialties and also available from Powerstrokeshop.com) 99288

Valve Cover Gasket (94-97)
(Ford) F4TZ-6584-A
(International) 1818350C2
(Napa) FPGVS50483R (too expensive at $79.99 ea last time I checked)

Cheers!
 

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OK Patrick beat me to it, I guess there is enough info for u (lol)

If that connector is melted it also can cause the injectors to miss fire. There are 5 pins in there. 2 out site pins are glow plugs, center pin is ground and other 2 are injector pins. When they melt it can cause a miss. You should consider replacing valve cover gaskets and under valve cover harness.s as well as repair the melted connectors. Look at this link and the first 3 pics are the pins and connectors.
Labeled Parts pictures from cars photos on webshots

Here are melted connectors on gaskets
PowerStroke Stuff III pictures from cars photos on webshots

part numbers

Valve Cover Harness Repair Kits (contains 4 hard shells w/seals, w/o terminals)
(Ford) F7TZ-14489-BA (94-96)
(Ford) F7TZ-14489-AA (97)
(International) 1830829C91 removal tool and Shells w/o pins
(International) 1661875C1 Pins
(International) 2501055C1 Pins with 6" wire
Valve cover harness replacement terminals:
Industry P/N 103935; Winzer Distributing (1-800-527-4126) selection number D52
Valve Cover Harness "Wedge" repair (not sure of years it fits or what it looks like)
(Ford) 2c3z-14a163-ab
Valve Cover Gasket (94-97)
(Ford) F4TZ-6584-A
(International) 1818350C2
Valve Cover Harness, under valve cover
(Ford) F4TZ-9D930-K (94-97)
(International) 1815923C92 (94-97)
 

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Discussion Starter #7
Smelled burnt wiring. Pulled the passenger side valve cover, melted connectors on the furthest forward pin, and the furthest back (the glow plug in the front on that side, and the glow plug in the back) on the harnesses under the cover.

I'm going to replace it all, but am wondering if there is a bigger picture I am missing here. Originally it was a fuel leak, and now I've got what is looking like two bad glow plugs simultaneously. I'm replacing all four plugs, and all wiring, but am I missing something?
 

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Smelled burnt wiring. Pulled the passenger side valve cover, melted connectors on the furthest forward pin, and the furthest back (the glow plug in the front on that side, and the glow plug in the back) on the harnesses under the cover.

I'm going to replace it all, but am wondering if there is a bigger picture I am missing here. Originally it was a fuel leak, and now I've got what is looking like two bad glow plugs simultaneously. I'm replacing all four plugs, and all wiring, but am I missing something?
May have bumped something while working ....They were already burned ....
 

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Discussion Starter #9
Replaced external and internal wiring harnesses on passenger side, replaced glow plugs (they looked fine), replaced vc gasket. Also, found another melted connector on driver side rear, replaced internal/external harness and gasket on driver side.

Slow to start, but seemed to do the trick, runs smooth. Now gotta get back to that fuel leak, and see if it is still around...

Thanks guys, I appreciate all the help.
 
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