Fuel System Pressure Test - 6.0L Diesel

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools

Illustration	Tool Name	Tool Number
	Adapter, High Pressure Pump Test	303-765

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release - 6.0L Diesel .
Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
Detach the coolant hoses from the air cleaner outlet pipe.

Fig 1: Locating Coolant Hoses & Air Cleaner Outlet Pipe

Courtesy of FORD MOTOR CO.

NOTE: Air cleaner side shown, engine side similar.

Loosen the clamps and remove the air cleaner outlet pipe.

Fig 2: Identifying Air Cleaner Outlet Pipe & Clamp

Courtesy of FORD MOTOR CO.

Loosen the clamps on the charge air cooler (CAC) duct at the intake manifold adapter

Fig 3: Charged Air Cooler Duct Clamp At Adapter

Courtesy of FORD MOTOR CO.

Loosen the clamp on the CAC duct at the CAC.

Fig 4: Charged Air Cooler Duct Clamp At Cooler

Courtesy of FORD MOTOR CO.

Remove and position the CAC duct aside.

Fig 5: Charged Air Cooler Duct

Courtesy of FORD MOTOR CO.

NOTE: The diagnostic pressure test port plug is located on the side of the secondary fuel filter housing.

Remove the diagnostic pressure test port plug.

Fig 6: Locating Diagnostic Pressure Test Port Plug

Courtesy of FORD MOTOR CO.

Install the special tool.

Fig 7: Identifying Special Tool (303-765)

Courtesy of FORD MOTOR CO.

Install a commercially available fuel pressure gauge.

Fig 8: Installing Commercially Available Fuel Pressure Gauge

Courtesy of FORD MOTOR CO.

Position the CAC duct and the air cleaner outlet pipe into place.
Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.

NOTE: It may take more than one key cycle to pressurize the fuel system.

Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine.

NOTE: Allow the vehicle to run before taking any fuel pressure readings to make sure that all air is out of the fuel system to prevent inaccurate readings.

Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to SPECIFICATIONS .

Fig 9: Testing Fuel System Pressure To Make Sure It Is Within Specified Range

Courtesy of FORD MOTOR CO.

NOTE: Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place the fuel in a suitable container.

If the commercially available fuel pressure gauge has a drain valve, open the drain valve and release the fuel system pressure.

Fig 10: Opening Drain Valve & Releasing Fuel System Pressure

Courtesy of FORD MOTOR CO.

When the fuel system pressure test is complete, install the diagnostic pressure test port plug.
- Tighten to 7 Nm (62 lb-in).

Fig 11: Locating Diagnostic Pressure Test Port Plug

Courtesy of FORD MOTOR CO.

Position the CAC duct into place.

Fig 12: Charged Air Cooler Duct

Courtesy of FORD MOTOR CO.

Tighten the clamp on the CAC duct at the CAC.
- Tighten to 12 Nm (9 lb-ft).

Fig 13: Charged Air Cooler Duct Clamp At Cooler

Courtesy of FORD MOTOR CO.

Tighten the clamps on the CAC duct at the intake manifold adapter
- Tighten to 12 Nm (9 lb-ft).

Fig 14: Charged Air Cooler Duct Clamp At Adapter

Courtesy of FORD MOTOR CO.

NOTE: Air cleaner side shown, engine side similar.

Install the air cleaner outlet pipe and tighten the clamps .

Fig 15: Identifying Air Cleaner Outlet Pipe & Clamp

Courtesy of FORD MOTOR CO.

Attach the coolant hoses to the air cleaner outlet pipe.

Fig 16: Locating Coolant Hoses & Air Cleaner Outlet Pipe

Courtesy of FORD MOTOR CO.