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Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine OFF) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately (1 – 2 seconds) rise to specification. Abnormally long periods of cranking to restart a hot engine that has been shut down for a short period of time may be caused by: Fuel pressure bleeding past a fuel injector(s). Fuel pressure bleeding past the check valve in the fuel pump module. 1. Disconnect the fuel inlet line at fuel rail. Refer to Fuel Tubes/Lines/Hoses and Clamps for procedures. On some engines, air cleaner housing removal may be necessary before fuel line disconnection. 2. Obtain correct Fuel Line Pressure Test Adapter Tool Hose. Tool number 6539 is used for 5/16″ fuel lines and tool number 6631 is used for 3/8″ fuel lines. Fig.7 Connecting Adapter Tool (Typical) 3. Connect correct Fuel Line Pressure Test Adapter Tool Hose between disconnected fuel line and fuel rail (Fig. 7). 4. Connect the 0 – 414 kPa (0 – 60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on the appropriate Adaptor Tool. The DRB III Scan Tool along with the PEP module, the 500 psi pressure transducer, and the transducer-to-test port adapter may also be used in place of the fuel pressure gauge. The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 5. Start engine and bring to normal operating temperature. 6. Observe test gauge. Normal operating pressure should be 339 kpa ±34 kPa (49.2 psi ±5 psi) . 7. Shut engine OFF. 8. Pressure should not fall below 30 psi for five minutes . 9. If pressure falls below 30 psi , it must be determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. 10. Again, start engine and bring to normal operating temperature. 11. Shut engine OFF. 12. Testing for fuel injector or fuel rail leakage: Clamp OFF the rubber hose portion of Adaptor Tool between the fuel rail and the test port “T” on Adapter Tool. If pressure now holds at or above 30 psi , a fuel injector or the fuel rail is leaking.

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ISSUE Some 2005-2008 F-Super Duty 250/350 vehicles equipped with a 5.4L 3V or 6.8L 3V engine may experience premature automatic shut off of the fuel fill nozzle, or repeated fuel shut off at the fuel station delivery nozzle with malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0191. Vehicles operated in muddy or dusty environments can encounter a dirt clogged carbon canister system. More specifically, the carbon canister’s vent, fresh air box, and filters become clogged with dirt from operating in such environments. SERVICE PROCEDURE Inspect the vehicle canister system and if it found to be dirt clogged then continue with this TSB. NOTE IF THE VEHICLE’S CANISTER SYSTEM IS NOT DIRT CLOGGED, THEN PROCEED WITH NORMAL DIAGNOSTICS AND DO NOT CONTINUE WITH THIS TSB. Vehicles with Pickup Boxes: 1. Replace the carbon canister assembly with a canister built after 10/1/2006. This canister has a revised internal filter media, and went into production on 10/1/2006. The date code is on a black sticker located on the carbon canister assembly. 2. Relocate the fresh-air intake port to a more protected location using the fresh air hose kit, for pickup applications only. 3. Replace fuel cap assembly if the vehicle was built before 5/16/2007. Vehicles with Pickup Box Removed or Chassis Cab: 1. Replace the carbon canister assembly with a canister built after 10/1/2006. This canister has a revised internal filter media, and went into production on 10/1/2006. The date code is on a black sticker located on the carbon canister assembly. 2. Relocate the fresh-air intake port to a more protected location using QVM bulletin Q-132 at the body builder’s website – https://www.fleet.ford.com/truckbbas/index.htm for fresh air intake routing recommendations. 3. Replace fuel cap assembly if the vehicle was built before 5/16/2007.

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FUEL PRESSURE RELEASE Fuel Rail With Fuel Pressure Test Port 1. Disconnect negative battery cable. Remove fuel tank cap to release fuel tank pressure. 2. Remove protective cap from fuel pressure test port on fuel rail. Place one end of Fuel Pressure Gauge (5069) hose into approved gasoline container. Screw remaining end of fuel pressure gauge hose onto fuel pressure test port. Fuel pressure will be released into gasoline container. 3. After fuel pressure is released, remove fuel pressure gauge hose from fuel pressure test port. Reinstall protective cap on fuel pressure test port and fuel tank cap. Reinstall negative battery cable. Fuel Rail Without Fuel Pressure Test Port 1. Remove fuel pump relay from Power Distribution Center (PDC), located near windshield washer reservoir. Refer to label on PDC cover for relay location. 2. Start engine and allow to idle until engine stalls. Attempt to start engine several times. Once engine will not restart, turn ignition off. 3. Disconnect electrical connector from any fuel injector. Connect a jumper wire between one fuel injector terminal and positive battery terminal. Connect another jumper wire to remaining fuel injector terminal. CAUTION: DO NOT apply battery voltage to fuel injector for more than 4 seconds, or fuel injector may be damaged. 4. Momentarily touch remaining end of jumper wire to negative battery terminal for no more than 4 seconds. Cover fuel line at fuel rail with shop towel before disconnecting. Disconnect fuel line. 5. Disconnect jumper wires. Reinstall electrical connector on fuel injector. Reinstall fuel pump relay. Diagnostic Trouble Codes (DTCs) may be stored in Powertrain Control Module (PCM) when ASD relay is removed. To clear DTCs from PCM, see TESTS W/CODES – 2.5L article. FUEL PRESSURE TEST

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1. Connect Rotunda High Fuel Pressure Adapter 014-00931-3 or equivalent to the Schrader valve mounted in the fuel regulator block on the side of the fuel filter housing. 2. Connect a line for a 160 psi gauge to the adapter 3. Run the engine at low idle and check for leaks in the gauge. 4. Operate the engine at high idle (maximum engine speed out of gear with brake set and wheels blocked). 5. Fuel pressure should be at least 30-70 psi . 6. Repeat this test for both front and rear tanks. 7. If fuel pressure is low, replace fuel filter and repeat this test.

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6.0L DIESEL FUEL IN ENGINE COOLANT DIAGNOSTICS FORD: 2003-2005 Excursion 2003-2007 F-Super Duty 2004-2008 E-Series ISSUE Some 2003-2005 Excursion, 2003-2007 F-Super Duty and 2004-2008 E-Series vehicles equipped with a 6.OL engine may exhibit fuel in the engine coolant, due to leaks in the cylinder head fuel injector area. Symptoms may include fuel in engine coolant and coolant expulsion from the degas bottle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Inspect the degas bottle for evidence of fuel in engine coolant. If diesel fuel is present, refer to the following Service Procedure. If not, follow normal diagnostics. NOTE IT IS VERY IMPORTANT TO ENSURE A COMPLETE FLUSHING OF THE ENGINE COOLING SYSTEM IS PERFORMED TO REMOVE ALL CONTAMINANTS FOLLOWING REPAIR. 1. Drain coolant from cooling system. 2. Remove all injectors from both cylinder heads. Refer to Workshop Manual (WSM), Section 313-04C. 3. Wipe injector bore clean of oil and fuel then apply a thin layer of bubbly type liquid hand soap, dish soap or laundry soap inside each injector bore. Ensure injector sleeve lip and cylinder head casting are coated with a soap layer. (Adding a small amount of water to the soap aids in creating bubbles) 4. Fit the cooling system pressure tester, refer to WSM, Section 303-03. (Do not add coolant) 5. Apply 5-10 psi (34-69 kPa) of air pressure to sealed cooling system. It is suggested to use a hand operated pressure tester or regulated shop air with tee in degas hose to degas bottle. NOTE MORE THAN 10 PSI (69 kPa) AIR PRESSURE CAN PUSH THE SOAP FROM THE LEAK POINT AND NO BUBBLES WILL BE PRESENT OR CREATED, MAKING DIAGNOSIS DIFFICULT. 6. Inspect each injector bore for bubbles. (A light and mirror or bore-scope may aid in pinpointing a leak location.) If bubbles are observed, determine if bubbles originate from the injector sleeve lip (Figure 1) or cylinder head casting. (Figure 2) Refer to cutaway view of the cylinder head. (Figure 3) a. Replace the injector sleeve if found to be leaking at sleeve lip, refer to WSM 303-04C. b. Replace cylinder head if leaking through casting, refer to WSM 303-01C. c. Flush cooling system, refer to another applicable Technical Service Bulletin (TSB) for proper cooling system flush procedures.