Recently had my engine replaced after 4 injector and 1 turbo failures in 5 months, along with a washed and galled cylinder. When the truck went in to the dealership, I had installed the bypass line between the fuel feed and return ports on the CP3 (see Superduty post on this), along with a full FASS 95. Once the factory rep was satisfied that this in no way could have caused the injector failures, the repairs were covered under warranty - call it luck or persuasion...
Anyway, when I got the truck back, it ran better and quieter than when new. After 1000 miles, this weekend I installed a FP gauge, and removed the bypass to hook up the gauge at the CP3. I installed the banjo bolt at the CP3 end of the line that came from under the OEM filter canister, which was the rearmost CP3 line/port (see anything wrong here?). Gauge showed good pressure (18 psi), truck started fine, and then died after 30 seconds at idle. Re-checked my install, realized via some posts here that I should have the gauge line hooked to the foremost CP3 port - made the swap, gauge showed no pressure, truck would still idle for 30 seconds and die.
After pulling my hair for an hour or so, the bulb came on - the service tech had disconnected the CP3 lines at the rear metal/rubber line junctions, and then hooked them up in reverse (front port hooked to fuel rail/canister return, rear port hooked to feed from filter canister) - the truck ran like a top for 1000 miles in this configuration, and had full power as far as I could tell, saved only by the "full loop" fueling system provided by the bypass line! Switched the lines to proper, all is good now. As I took this as proof positive of the bypass' capability to keep fuel going to the CP3 under adverse conditions, I will be moving the FP gauge line to the bottom of the filter canister and replacing the bypass as soon as I get more banjo bolt sealing washers...
One question - truck runs fine now, but is there any chance the CP3 or anything else was damaged by the tech's mistake? What (or how) should I check this?

 

Wow, an amazing story! I really doubt that anything was damaged by this tech's mistake, but I would still have it documented by your dealer just in case.

I'm just curious, did they ever determine the cause of the numerous injector problems?

 

Has anyone posted pics or diagram of the fuel flow on the 3rd gen trucks, specifically for the '06?

Just trying to understand the fuel system.

TIA

Tony

 

Me too! (cept '03)

JRG