Ford Powerstroke Diesel Forum banner

Diagnosing low fuel pressure

Tags
ford 6.0
1 reading
17K views 7 replies 4 participants last post by  Hydro  
#1 ·
Hey guys and gals, back again with yet another issue on my 2005 6.0 powerstroke.
Finally had the truck running amazing after other issues, and now it sits in the shop dead again. I believe it’s due to a fuel delivery issue, and I’m looking for help diagnosing it this weekend.
About a mile from work one morning, I noticed a big loss in power from the truck, so I limped it the rest of my way and it would hardly idle, shut it down wouldn’t restart. Left it alone and went on with my day, once the moon came out and the workday ended I went back to the truck with a scanner, HD to cycle the key a few times to do a pairing procedure with the scanner, then it fired right up. Took it for a drive watching my icp and all the jazz on the HPO system thinking I would find another leak. It would idle just fine, took it for a rip ran great under 2000rpms, gave it a WOT pull and it wouldn’t give me anything more than 2500rpms, then started missing really bad and eventually stalling out. All my numbers were right where I wanted them to be on the scanner. So I ruled out a leak in the hpo system, and did a quick injector buzz test. All 8 passed. Now I belive I’m running the truck on low fuel pressure, to the point where the injectors run dry eventually stalling out. That brings me to here, a week later installing a glow shift fuel pressure gauge in the truck to see what’s up.
anyways, assuming that I’m not getting proper fuel pressure, and probably ruined some injectors what’s the best way to diagnose this issue? Idon’t really know where to start, and don’t want to dump money into a bunch of parts that I don’t know forsure aren’t bad.
If anyone can help me with some procedures to diagnose this issue, and any pointers and help would be great!
here’s a list of things done to the truck incase it helps
Blue spring upgrade, EGR delete, new oil cooler, 4” turbo back exhaust, turbo rebuild kit, coolant filter, standpipes dummy plugs and nipple cup seals, replaced fuel filters maybe 1500km ago, 5w40 synthetic oil (it’s really cold here in sask now). And the truck is burning winter diesel
Truck has 252xxxkm on the clock
 
#3 · (Edited)
Santa Clause is something to believe. Fuel pressure is something to be measured. ;)

Two things come to mind with your symptoms.

One - test fuel pressure at the test port on the secondary filter housing. It's low on the front of the housing and has an allen head plug in it. Yes, verify pressure at idle but the best way is during WOT while driving. A good pull accelerating through all the gears will make low pressure quite evident on a gauge. Low pressure could be the pump, primary filter/cap not fully seated, restrictions and of course air.

Two - yes, these injectors will suffer internal damage if subjected to continual low fuel pressure conditions. In fact, there is actually a "negative" fuel pressure condition created when fuel supply pressure is too low to charge the injectors and that is when the damage occurs. One thing that is not always easy to diagnose is an injector with a sticking delivery valve (pintle) that leaks combustion gasses into the injector, then the fuel rail displacing the fuel with combustion gasses, even to the point of emptying the secondary filter housing. The same thing can occur with a leaking compression seal - the metal gasket on the bottom of the injector. These concerns gradually worsen and may present only after the engine was warmed up to operating temperature to begin with. Especially the sticking delivery valve scenario. A power balance test with a visual display can be very helpful in identifying this as will the bubble or balloon test as Ford calls it. Power balance will usually show the injectors on one cylinder bank dropping out.
 
#4 ·
Installing a

Installing a gauge to that port right now as we speak will hopefully be able to get you guys some numbers soon on fuel pressure, as of right now I would belive that I have enough pressure to keep it running at lower rpms but as I try to pump more fuel through it for some reason it just can’t get the fuel it needs, hoping it’s something simple but with my luck I’ll be chasing it for months. Is there any way to test the injectors without running a test on the scanner? All I can do with mine buzz test them unfortunately
 
#8 ·
Less than 1/4 tank of fuel, if the pickup foot is broken and you will "suck air" -- also the broken parts can get sucked into the line and partially plug it - causing low flow in demand

Your gauge should tell the story, when you get operational
 
owns 2006 Ford F250 Lariat FX4
  • Like
Reactions: Heavy_GD