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6.0L Power Stroke Diesel 2003 - 2007 F250, F350 pickup and F350+ Cab Chassis, 2003 - 2005 Excursion and 2003 - 2009 van

Foaming Fuel

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Old Jul 2, 2019 | 09:12 AM
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From: Suffolk, VA
Foaming Fuel

I've found a few threads but final outcome was posted. 2004.5 Ex with 6.0, and when we purchased it the water in fuel light was on. Fixed that by draining the tank and cleaning it out. I used the HFCM to remove fuel from the tank and found foam coming out of the HFCM. I put a tube on inlet and outlet from a bucket of fuel to eliminate the lines from the tank and have same amount of foam. I replaced the filter, cap(mangled by PO), manifold(had crud in it) and drain plug(had threads gone). I pulled the HFCM and vacuum checked at all 4 lines, use 10 psi shop air and soap/water to leak check and didn't find any leaks. Fuel pressure at idle is 57, WOT is 51. I have a blue spring kit but wanted to fix the foaming first. Can the pump itself be bad because of the water that was in the system? I literally have no other issues with the truck.
 
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Old Jul 2, 2019 | 02:52 PM
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From: Spanaway
If you did not block off the return line from the engine it will pull in air and cause foam.
 
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Old Jul 2, 2019 | 07:14 PM
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I was wondering about that, I haven't had a chance to check the secondary filter bowl with the key on to see if it foams there as well. Thanks.
 
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Old Jul 3, 2019 | 01:47 AM
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From: Spanaway
Two lines on tha tank side are one suction and the other hot fuel return to tank.
On the engine side you have pressure feed and a return from the pressure regulator.

There is a test for fuel aeration. I don't have the PDF handy. You will find the info
in your year PC/ED book. It's the black book in the shop manual set.
 
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Old Jul 6, 2019 | 07:43 AM
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Originally Posted by Yahiko
If you did not block off the return line from the engine it will pull in air and cause foam.
Turns out that was exactly what I needed to do. Did that and the KOEO to check the filter bowl, then did the bubble test. All good. Guess I was being a little paranoid about ruining injectors. Thanks!
 
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Old Jul 6, 2019 | 03:27 PM
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From: Spanaway
Good to hear that you got a good answer to that quest.
 
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