Low fuel pressure will damage injectors

6.0 POWERSTROKE FUEL PRESSURE

TESTING AND TIPS

WHAT CAUSES INJECTOR FAILURE

This chart is from FORD. As you can see, we need to do our part to ensure
the customer gets good service without un-needed repairs. Many repeat
repairs can be attributed to improper filter replacement or service.

FUEL SYSTEM DIAGNOSTICS

Check fuel pressure at
the test port in the
secondary filter housing

Checkregulatorand
returnlinesfor
restriction

Flushsystem;Replace
fuelandfilters

Samplefuel
Badfuel
Inspectreplacefuel
filtersandretest

Amprampand
voltagedrop
fuelpumpand
wires

Checkforfuel
inletrestriction.
Checkpressure
regulator.

Repairwiringor
replacefuelpump

Repairrestrictionor
pressureregulator

FUEL TEST PORT

If fuel pressure drops

below 38 psi under heavy
load, there is a fuel
delivery concern. Always
verify fuel pressure under
load.
Fuel
pressure
testport

Eseriesbackofeachhead

Fseries

FUEL PUMP AMPERAGE

D/C COUPLE

A/C COUPLING

PRIMARY FILTER

Primary filter removed

10 micron filter
After fuel is drawn from
tank and conditioned it
flows to secondary filter

SECONDARY AND PRIMARY FUEL FILTERS

SECONDARY FILTER

Four micron filter

Mounted next to oil filter
on top of engine
Secondary filter also
houses regulator valve
Returning excess fuel to
return line
also incorporates an
orifice at the top of
housing to bleed any air
out of fuel
8

INLET RESTRICTION TEST

Low fuel pressure and

volume could be caused by
tank restriction
Check inlet side of
horizontal fuel conditioning
module for a vacuum
Tee in vacuum gauge with
fuel inlet
Five six inches of vacuum
maximum
Higher than five or six
inches of vacuum check fuel
inlet line and tank
9

FUEL AERATION TEST

Remove return line at

horizontal fuel control
module
Install clear hose on
return line and run into
clean container
Operate engine at WOT
for a short time and
watch for bubbles in
clear hose
10

WATER DRAIN

Located on the side of

fuel conditioning
module located on
drivers side frame rail
There is a casting plug
on Fuel housing has to
be removed to drain
water

11

MULTIPLE CYLINDERS SAME SIDE LOW ON

POWER?

The fuel supply line on the front of both heads has a banjo bolt with a flow valve in it. This
valve can restrict with contaminants. All 4 cylinders on the bank will have low power or
misfire concerns. To verify the concern, check fuel pressure at the back of the head
involved.

BAD COMPRESSION RING

Ifthisconcernhasexistedfora
periodoftime,keepinmindall
4injectorsonthatsideofthe
engineshouldbereplaced.Air
canbecompressedsothe
injectorgetspoundedanddoes
nothavetheamountoffuel
neededtolubricateandremove
heat.
Coppersealingringsmustbe
replacedanytimetheinjectoris
removed.Theyareonetime
sealsonly.

13

TIP-PwrBal. Test can find

the worst of the bunch for
us to
Start with
Upperfueloring
Fuelinlet
Lowerfueloring

Compression

POOR RUN FUEL PRESSURE OK

Multiplecylindermisfirecan
becausedbyoneinjector
allowingcompression
pressuretobypassthe
copperinjectorcompression
sealandfueloringcausing
severeaerationofthefuel.
Todiagnosethisconcernjust
removethesecondaryfuel
filter.Removefuelpump
voltagefeedorfuelpump
relay.Removethecamor
cranksensorwire,crankthe
engineandlookforair Youcanremovetheleftorrightfuellinetodeterminewhatbank
bubblesinthefuel.
hastheconcern.Butkeepinminditwillbetheonewiththe
misfires.

FUEL LEAKS INTO THE OIL?

Boltscanbreakand
causeafuelleak.

Oil leak
Alwayschecktheoillevelbeforeyouservicea6.0powerstroke.Iftheoillevelistoohigh,suspectfuel
leakingintoit.Pullthedrainpluguntiltheoilstopsleaking.Runthefuelpump.Iffuelleaksoutofthe
oildrain,youfoundaproblem.Blockthefuelflowtooneheadtoisolatewhatbanktheleakison.
Fuelcontaminationcanhurttheturboshaftandbearings.

FUEL INLET RESTRICTION OR AIR LEAK

Installaclearloopedhoseinthe
fuelreturnline.Holdtheengine
RPMatasteady2000.Verifythere
arenoairbubbles.

Insertavacuumgaugeintheline
betweenthetankandfuelpumpinlet.
Iffuelpressurewaslow,ensure
vacuumstaysunder3inchesatidle
anddoesnotexceed7inchesunder
highRPMandload.Ifvacuumishigh,
checkforarestrictedfuelpickupor
line.

HFC MODULE NEW DESIGN

IfyoureplacetheHFCmodule,you
makegetanewerdesignthatno
longerhasthefuelheater.Thereis
amoldedholewheretheheater
went.Thereisalsoareplacement
harnessthatremovestheelectrical
plug.

NEW HARNESS HAS 3 CONNECTORS

18

OLD HARNESS HAD 4 CONNECTORS

19