How i primed the 6.4 fuel system - Ford Powerstroke Diesel Forum
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Old 03-10-2014, 01:21 PM
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How i primed the 6.4 fuel system

My idea may already be on the forum, but as a dodge tech, I was not familiar with the 6.4 fuel system. The truck I worked on was a 2008 f450 6.4. The truck was throwing the water in fuel light. I tried to simply pull the lever and drain it but after draining it 10 times, I constantly saw mold coming out of the valve. I got both new fuel filters (frame mount and high mount filters). I do fuel filters on the cummins all the time, and boy was I in for a task after doing the powerstroke. I ended up having to remove the filter/pump housing, take it apart and clean it out. It was inreal how much mold was growing in there. Previous owner obviously has not changed the filter in a long time. I was not aware of the procedure everyone online goes by. Anywho, I did them both at the same time. Therefor all lines were dry.

After 3 hours on trying to prime the system, I got desperate and decided to hook air into the filler cap and forced the fuel up top (with the fuel pump running) and it FINALLY primed. The first time I hooked air, I had the engine mount fuel filter out and pushed air in the fuel tank until it filled the bowl. Then I put the new filter in and cracked the banjo bolt on the fuel fitting and hit it with air again until a solid stream of fuel came out. About 10 seconds of turning the engine over, it finally crank up and ran. No sputtering, no hesitation; full power.

Im sure someone here will tell me hooking air to the tank is a very bad idea, and it might be. But as desperation came, it was the only thing that worked for me. Maybe it will help someone out in the future
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Old 03-10-2014, 01:24 PM
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I must point out that I DID NOT PUT SHOP AIR IN THE TANK! I had a hand held air valve and barely let air in the tank. I would guess I had about 2-5psi in the tank. just a rough estimate.
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Old 03-10-2014, 01:28 PM
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it seems like something had to be a restriction for the air PSI to overcome what a normal key cycling procedure would not

as far as air into the tank I commend u on getting er done
i see you didn't use shop air = smart

but to anyone who tries this u would be shocked at what even 5 psi can do to the shape of plastic fuel tank if not vented so be very careful
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Old 03-10-2014, 02:00 PM
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Well the pump is in the filter housing. it was 100% air when I put it back in. Fuel pump was priming air, and had no fuel to make a suction. I tried putting fuel into the lines at the upper filter to fill up the lower filter, but it was not working for me.


As for the psi in the tank, I agree! It was a little sketchy, but I knew it was pushing fuel out of the lines and not over pressurizing the tank, so I wasn't too stressed about it.
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