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ISSUE Some F-Super Duty vehicles equipped with the 6.4L diesel may exhibit one or more of the following concerns: lacks power, leaks oil, fuel or coolant from the tail pipe, abnormal tailpipe sediment, white smoke or ash, exhaust smell, knock or rattle, elevated idle, surge, crankcase oil level over-full, MIL On, DTC’s P0087, P2291, P0263-P0284, P0300-P0308, P1336, P132B, P2262, P2263, P244C or P244D. ACTION To diagnose and correct the concern, refer to the following Service Procedure. SERVICE PROCEDURE NOTE DO NOT START ENGINE Evaluation, Inspections, And Checks 1. Retrieve KOEO diagnostic trouble codes (DTCs). 2. Check oil level. Remove and clean dipstick. Reinsert into dipstick tube only until dipstick handle reaches top of dipstick tube (Figure 1). NOTE 3. Check coolant level. 4. Check fuel quality. 5. Inspect tailpipes for abnormal sediment; for example black soot, white ash, oil, coolant, or fuel. 6. Inspect vehicle for coolant, oil and fuel leaks at the following locations: • Tailpipes

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Some F-Super Duty vehicles equipped with the 6.4L diesel may exhibit one or more of the following concerns: lacks power, leaks oil, fuel or coolant from the tail pipe, abnormal tailpipe sediment, white smoke or ash, exhaust smell, knock or rattle, elevated idle, surge, crankcase oil level over-full, MIL On, DTC’s P0087, P2291, P0263-P0284, P0300-P0308, P1336, P132B, P2262, P2263, P244C or P244D. ACTION To diagnose and correct the concern, refer to the following Service Procedure. SERVICE PROCEDURE NOTE DO NOT START ENGINE Evaluation, Inspections, And Checks 1. Retrieve KOEO diagnostic trouble codes (DTCs). 2. Check oil level. Remove and clean dipstick. Reinsert into dipstick tube only until dipstick handle reaches top of dipstick tube (Figure 1). NOTE Figure 1 – Article 07-8-9 3. Check coolant level. 4. Check fuel quality. 5. Inspect tailpipes for abnormal sediment; for example black soot, white ash, oil, coolant, or fuel. 6. Inspect vehicle for coolant, oil and fuel leaks at the following locations: • Tailpipes • • • • • • Up-pipe joints Exhaust manifolds to cylinder heads Exhaust manifolds to up-pipes Charge air cooler system and air inlet system Oil separator Inside air filter housing NOTE 2. If oil is over full, drain and fill crankcase with new oil setting the level to the middle of the hash marks. 3. Remove valve covers; refer to Workshop Manual (WSM), Section 303-01. 4. Remove lower charged air cooler CAC hose. Inspect for fuel and oil contamination. Clean as required and reinstall.

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NOTE: 1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Install a fuel pressure gauge between fuel pressure regulator and fuel distributor pipe. See Fig. 1 . Bleed air from fuel line going to pressure gauge. 2. Unplug fuel pressure regulator Vacuum Switching Valve (VSV) connector on right side fender skirt. This is a 4-wire connector with Black and Blue wires in harness. PCM controls VSV to cut vacuum to fuel pressure regulator during hot engine starts. 3. Start engine and measure fuel pressure at idle. Disconnect fuel pressure regulator vacuum hose. Note fuel pressure at idle with vacuum hose disconnected (no vacuum). Fuel pressure should be 42 psi (3.0 kg/cm2 ). See FUEL PUMP PERFORMANCE . 4. If fuel pump pressure is low, check for fuel leaks, restrictions in intake side of fuel pump, leaking injectors, faulty pressure regulator or faulty fuel pump. If fuel pressure is high, check for restrictions in return line to tank or faulty pressure regulator. If pressure does not change when pressure regulator is disconnected, replace pressure regulator. 5. Reconnect pressure regulator vacuum hose and check fuel pressure (with vacuum). Fuel pressure should be 35 psi (2.4 kg/cm2 ). Apply battery voltage to VSV connector Blue wire terminal, and ground Black wire terminal (with vacuum). See Fig. 2 . Fuel pressure gauge should read about 42 psi (3.0 kg/cm2 ). If fuel pressure is not within specification, check for defective VSV. 6. Disconnect and plug vacuum hose from fuel pressure regulator. Stop engine and ensure fuel pressure remains greater than 35 psi (2.4 kg/cm2 ) for 4 minutes after engine stops. 7. If pressure drops, check for leaking injectors, faulty pressure regulator or bad check valve in fuel pump. If engine does not start, by-pass fuel pump relay to check for fuel pressure. Remove fuel pump relay from underhood fuse/relay box. Connect a fused jumper wire between terminals No. 1 and 3 of fuel pump relay connector in fuse block. See Fig. 3 and Fig. 4 . 8. If fuel pump does not operate, check for battery voltage to terminal No. 3. If battery voltage is present, check for open in fuel pump circuit. If fuel pump operates with jumper wire installed, check fuel pump relay and relay energizing circuit. Repair as necessary. Begin basic fuel system diagnosis with testing fuel pressure.

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IMPORTANT: Inspect the fuel tank internally and clean the fuel tank if you find a restricted fuel filter. 1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Clean all the fuel filter connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system. 4. Disconnect the threaded fittings (1, 2) from the fuel filter. 5. Remove the fuel filter bracket bolt (4). 6. Cap the fuel pipes in order to prevent possible fuel system contamination. 7. Slide the fuel filter from the bracket. 8. Inspect the fuel pipe O-rings for cuts, nicks, swelling, or distortion. Replace the O-rings if necessary. INSTALLATION PROCEDURE 1. Slide the fuel filter into the bracket. 2. Remove the caps from the fuel pipes. NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the threaded fittings (1, 2) to the fuel filter. Tighten ^ Tighten the fittings to 25 N.m (18 lb ft)Tighten the fuel filter bracket bolt (4), to 12 N.m (106 lb in). 4. Lower the vehicle. 5. Tighten the fuel filler cap. 6. Connect the negative battery cable. 7. Use the following procedure in order to Inspect for leaks. 7.1. Turn ON the ignition, with the engine OFF, for 2 seconds. 7.2. Turn OFF the ignition for 10 seconds. 7.3. Turn ON the ignition, with the engine OFF. 7.4. Inspect for fuel leaks. 7.5. Install the engine sight shield

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REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Disconnect the negative battery cable. 3. Remove the intake manifold assembly. 4. Remove the fuel injector electrical connectors by pushing in the wire connector clip and pulling the electrical connector away from the fuel injector. 5. Remove the fuel feed inlet pipe at the rail (2). 6. Remove the fuel rail attaching bolts. 7. Lift the fuel rail assembly from the cylinder head. INSTALLATION PROCEDURE IMPORTANT: Lubricate the fuel injector O-rings with clear engine oil before installation. 1. Insert the fuel rail into the cylinder head. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel rail attaching bolts. Tighten Tighten the fuel rail attaching bolts to 24 N.m (18 lbs ft) . 3. Install the fuel feed inlet pipe to the fuel rail (2). IMPORTANT: Rotate the fuel injectors as required to avoid stretching the wire harness. 4. Install the fuel injector electrical connectors. 5. Install the intake manifold assembly. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 6. Reconnect negative battery cable. 7. Inspect for fuel leaks through the following steps: 7.1. Turn ON the ignition, with the engine OFF for 2 seconds . 7.2. Turn OFF the ignition for 10 seconds . 7.3. Turn ON the ignition, with the engine OFF. 7.4. Inspect for fuel leaks.