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6.0 Powerstroke extremely low fuel pressure! Help please

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21K views 6 replies 3 participants last post by  robert61092  
#1 ·
Hello, good evening everyone! I just registered here, but I have been lurking for quite awhile and have learned a lot from everyone here, so thank all of you that contribute to this site. Also this is my first post, so I applogize in advance if I went about this the wrong way. Now on to my problem, it is a very long story I am going to do my best to give you the short of it.

About a month ago my 05 6.0 crew cab short bed developed a bad miss. I took it down to the ford dealership, ford put it on the IDS scanner and said #7 injector was bad and #3 was low. I was quoted $1600 for 2 injectors, fuel filters changed and driver side valve cover leak fixed.

Being mechanically inclined, I opted to do the repair myself. First I changed #3 and #7 injectors. Truck ran awesome for about 100 miles. Miss came back, put it on “torque” my ob2 scanner/android. Cylinder 5 contribution now showed. I went ahead and swapped number 5. Truck ran great. Another 200 miles, cylinder 1 contribution light came on. I went ahead and tore it back down and replaced cylinder 1 injector, while I was there, the last time. I changed the stand pipe and dummy plug. Got it all back together, the truck ran and runs perfect.

About 100 miles after the passenger side injectors swap, now when I get on the interstate at cruising speed, the truck shakes, misses and shuts off. At this point I tested/ checked everything. I’ve checked/replaced:

FICM-48v/47.5v lowest it has gotten.
Replaced Injector harness.
Replaced oil, with motorcfraft 15w-40
Replaced both fuel filters.
Replaced Horizontal fuel pump/driver side frame rail.
Did blue spring update.

I’ve tested the FICM, ICP, IPR all of these are in spec and the truck fires right up no problem, to diagnose fuel pressure, I ordered secondary aluminum fuel filter cap, with 1/8 fitting. From there, I ran a 0-100 psi fuel gauge to the windshield and took off down the road. Idling fuel pressure is 70psi (blue spring update). Cruising around town fuel Pressure drops between 30-40psi. WOT, fuel pressure will drop completely all the way down to 0psi. I have checked and switched gauges, at this point I was sure it was the fuel pump, so today I swapped it out. No dice. Truck still has the Same issue. While changing fuel pump I also put in new fuel filters. Today, while changing the fuel filters, when I turn the key on, to “prime” the filters, I took the secondary fuel bowl off and watched to see if air is in the system. To my surprise, when the key is switched on, the fuel bowl bubbles almost like the fuel is boiling. It will bubble/explode out of the fuel bowl. While doing this, you can hear air switching/gurgling. I have no idea where to go from here or what to do. I do have videos of the fuel bowl, which can be seen here. I have been without my truck for a month now and have spent a lot of money to get it going again. I’m at my wits end and officially stumped at this point and really need some help.

https://youtu.be/MAc8kkZ7zH8
 
#2 ·
You need the chase the fuel suction line back to the tank to see if there is damage(I had a critter bite mine) also the pickup foot screen in the tank may have junk plugging it. -- Fuel at the upper filter bowl should flow out clear and quick.
That low pressure is likely why you have replaced so many injectors -- really a fuel gauge would be one of my permanent additions, along with oil pressure and EGT
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Just watched the vid -- the fuel pump should run without cranking the engine -- do you get bubbles like that, or do you have to crank?
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owns 2006 Ford F250 Lariat FX4
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#3 ·
Reason I asked about needing to crank -- compression can be introduced into the fuel rail by a leaking injector or copper washer. -- need to determine if this is a supply issue or a leaking injector seal.
 
owns 2006 Ford F250 Lariat FX4
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#4 ·
Hey brother, thanks so much for the help/ response. Initially I thought this was a simple injector repair, but after the Injectors, more injectors continued to “drop out”. After weeks of working on it (only have time after work) I have discovered. The low fuel pressure is what has been killing the injectors all along. I ordered a fuel pressure gauge and will be installing one within the week, to keep an eye on it at all times.

In the video, the fuel bowl bubbles like that, with just the key on. The fuel pressure goes up to 45psi, then drops back down to 0, then fire it up and it idles at 65psi.

When I turn the key on, the fuel bowl begins to rapidly bubbly over like that, and has air purging out/gargling sound.

When I pulled the 304 FICM relay with fuel bowl off and turned the engine over, it produced the same results. As soon as your turn the key over it bubbles over like that. Then will continue to as your turn the motor over. All 4 injectors were replaced on the passengers side. How do I test the injectors to make sure they sealed correctly? And where do I begin chasing these issues? I’m new to the 6.0. I have drove the truck maybe 2,000 miles then out of no where problem after problem.
 
#5 ·
I just replaced the 4 injectors myself, so I guess it is very possible, they did not deal properly. I just don’t know how to go about checking that correctly. Also, how do you recommend I go about, reinstalling the injectors/re seating them/sealing. Thanks for any help man.
 
#6 ·
To test just the injectors you would fill the fuel bowl to the top -- then use the starter jumper wire on the passenger fender to crank the engine -- this takes the fuel pump out of the picture. No bubbles in the fuel bowl = good. -- crank about 15 seconds a couple of times.

Does the fuel drain back when the key is off? -- supposed to be a check valve in the fuel pump to keep the fuel from draining back. -- You can hook a length of clear hose onto the return fitting and run that into a container or back to the tank -- so there is less mess. The fuel pump should run for about 20 seconds at key on(could jump the relay to run it longer). That clear line should be bubble free.
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owns 2006 Ford F250 Lariat FX4
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#7 ·
Had a similar issue on a customer's truck, it ended up being dried out orings on the cover that seals the water separator and the different chambers on the frame mounted lift pump i also changed the oring on the drain plug for the water seperator and this solved the issue with air getting into my upper fuel bowl and the gurgling sound. had low power and high boost aswell as weird shifting issues like the tranny wouldnt shift till you hit high rpm and let off the pedal.
 
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