HPFP problems / Questions
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HPFP problems / Questions
I am in the process of Rocker arm replacement on my 6.4PS due to intake popping sounds that just started.
Prior to starting the teardown, I did some diagnostic scanning using my AE Proline. Here are some of the results (from my head as my laptop is at work)
Idle Fuel rail pressure = ~5500psi
Full power/boost FR press = ~24,500psi
Idle cyl balance test showed 0 deviation
Disabling the injectors one at a time, I discovered that cyl 7 showed slightly less drop at idle than the others.
Under full boost, Exhaust BP runs around 55-58, but never exceeds 60psi
No codes were detected, and none of the parameters I looked at appeared to be out of spec.
I started into the teardown and found metal particles in the fuel I drained from the rail & lines. I also found #7 exhaust rocker tip worn right down to the clip. This somewhat correlates with my cyl drop test results. I still have the LH side to do, expecting similar findings. Meanwhile, I have a few questions to ask.
Questions for the 6.4 Gurus:
1) I assume my HPFP is about to fail. Should I replace it ASAP or should I just drive it and keep a close watch on the fuel filters until it gets worse?
2) Is it typical to find metal particles in the injector lines and rails, but never find any in the filter bowl?
3) With the fuel rail pressures still being in spec, what are the risks of running the truck occasionally until I can purchase a new HPFP, injectors, Cooler, etc.?
4) Should I be concerned about metal particles potentially causing a sticking injector if I do run the truck?
5) Regarding flushing fuel system components:
a) How are the return passages in the heads cleaned?
b) What other components can be successfully cleaned Vs replaced?
6) Where is the best place to connect an LP system pressure gauge?
7) With 140,000km(87,500 miles) on the original head gaskets, would doing "studs only" be a good idea, or should I expect the HGs to let go in the near future if I add a mild tune?
8) Has anyone come up with a way to service/drain the frame mounted separator without taking a bath in fuel? when draining, mine always runs along the frame rail and drips everywhere, making the task VERY un-pleasurable, for personal, as well as environmental reasons.
Any help or suggestions regarding what I need to do next are welcome.
Thanks in advance.
A bit more history for those who care to read.
I own a 100% stock Job 1 2008 F250 with 140,000km(87,500 miles) that recently started a slight intake popping. At the same time, it also developed a slight limp on one cylinder when accelerating above 2000 rpm with moderate to high boost. Idle is stable/smooth and cold/hot starting is normal. The truck has also lost a very slight bit of performance over the last 20-30,000km (seat of the pants feeling only). I am religious with fuel filter replacement and system maintenance. I have religiously used Stanadyne Perf treatment at every fill up.
Since I'm doing this job with the cab on, in my tight garage, I need to get the truck out to make room for other jobs. For the time being, I plan on re-assembling the engine and getting the truck running so it can be shuffled around in the yard until I can afford to collect all the parts and raise the cab.
I plan on doing a DPT/CAT/EGR delete along with the required tune. I beat the truck occasionally, but don't have any desire for the hot tunes. While I have the cab up to do the HPFP & injectors, I also plan on doing studs.
This was also posted on a few other sites, so excuse me if some of you have read this elsewhere.
Prior to starting the teardown, I did some diagnostic scanning using my AE Proline. Here are some of the results (from my head as my laptop is at work)
Idle Fuel rail pressure = ~5500psi
Full power/boost FR press = ~24,500psi
Idle cyl balance test showed 0 deviation
Disabling the injectors one at a time, I discovered that cyl 7 showed slightly less drop at idle than the others.
Under full boost, Exhaust BP runs around 55-58, but never exceeds 60psi
No codes were detected, and none of the parameters I looked at appeared to be out of spec.
I started into the teardown and found metal particles in the fuel I drained from the rail & lines. I also found #7 exhaust rocker tip worn right down to the clip. This somewhat correlates with my cyl drop test results. I still have the LH side to do, expecting similar findings. Meanwhile, I have a few questions to ask.
Questions for the 6.4 Gurus:
1) I assume my HPFP is about to fail. Should I replace it ASAP or should I just drive it and keep a close watch on the fuel filters until it gets worse?
2) Is it typical to find metal particles in the injector lines and rails, but never find any in the filter bowl?
3) With the fuel rail pressures still being in spec, what are the risks of running the truck occasionally until I can purchase a new HPFP, injectors, Cooler, etc.?
4) Should I be concerned about metal particles potentially causing a sticking injector if I do run the truck?
5) Regarding flushing fuel system components:
a) How are the return passages in the heads cleaned?
b) What other components can be successfully cleaned Vs replaced?
6) Where is the best place to connect an LP system pressure gauge?
7) With 140,000km(87,500 miles) on the original head gaskets, would doing "studs only" be a good idea, or should I expect the HGs to let go in the near future if I add a mild tune?
8) Has anyone come up with a way to service/drain the frame mounted separator without taking a bath in fuel? when draining, mine always runs along the frame rail and drips everywhere, making the task VERY un-pleasurable, for personal, as well as environmental reasons.
Any help or suggestions regarding what I need to do next are welcome.
Thanks in advance.
A bit more history for those who care to read.
I own a 100% stock Job 1 2008 F250 with 140,000km(87,500 miles) that recently started a slight intake popping. At the same time, it also developed a slight limp on one cylinder when accelerating above 2000 rpm with moderate to high boost. Idle is stable/smooth and cold/hot starting is normal. The truck has also lost a very slight bit of performance over the last 20-30,000km (seat of the pants feeling only). I am religious with fuel filter replacement and system maintenance. I have religiously used Stanadyne Perf treatment at every fill up.
Since I'm doing this job with the cab on, in my tight garage, I need to get the truck out to make room for other jobs. For the time being, I plan on re-assembling the engine and getting the truck running so it can be shuffled around in the yard until I can afford to collect all the parts and raise the cab.
I plan on doing a DPT/CAT/EGR delete along with the required tune. I beat the truck occasionally, but don't have any desire for the hot tunes. While I have the cab up to do the HPFP & injectors, I also plan on doing studs.
This was also posted on a few other sites, so excuse me if some of you have read this elsewhere.
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Joined: Feb 2015
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I use a 1/2 gallon jug ... former life was windshield wiper fluid ... unscrew cap and hold mouth to water separator outlet tube. I never get any fluid on me when I drain it.
Can't help with metal in fuel rail questions.
What are you using to jack your cab up???
Only 87k miles!!
Can't help with metal in fuel rail questions.
What are you using to jack your cab up???
Only 87k miles!!
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Joined: Jan 2012
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I haven't lifted the cab yet, but will likely use 2 chain blocks and several cargo straps to suspend it from the roof structure of my neighbours shop with 12ft ceilings.
Yeah 87K miles and all this hits me.
Yeah 87K miles and all this hits me.
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