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1 Page 1 of Ford Pickup 6.4L Eng F250 Super Duty ENGINE CONTROLS - DESCRIPTION AND OPERATION - F250-F550 SUPER DUTY 6.4L (DIESEL ) FUEL SYSTEM The fuel system includes the following: low pressure fuel system that delivers the fuel from the fuel tank to the high pressure pump high pressure fuel system that increases the fuel pressure and delivers it to the fuel injectors fuel cooler system that cools the fuel returning from the injectors and the high pressure fuel injection pump

2 Page 2 of 6 Fig 1: Fuel System Courtesy of FORD MOTOR CO. Item Part Number Description 1 - Accelerator pedal position (APP) sensor 2 - Powertrain control module (PCM) 3 - Electronic circuit 4 - High pressure fuel to the fuel injectors 5 - Low pressure fuel to the cooler

3 Page 3 of Variable turbocharger geometry position sensor 7 - Engine coolant temperature (ECT) sensor 8 - Fuel rail pressure (FRP) sensor 9 - Exhaust gas recirculation (EGR) valve position sensor 10 - Mass air flow (MAF) sensor and intake air temperature (IAT) sensor 11 - Intake air temperature 2 (IAT2) sensor 12 - Exhaust pressure (EP) sensor 13 - Exhaust gas recirculation temperature (EGRT) sensor 14 - Exhaust gas temperature (EGT) sensor 15 - Engine oil temperature (EOT) sensor 16 - Manifold absolute pressure (MAP) sensor 17 - Crankshaft position (CKP) sensor 18 - Camshaft position (CMP) sensor 19 - Fuel Rail Temperature (FRT) Sensor 20 - Fuel cooling system 21 - Low pressure fuel pump 22 - Secondary fuel filter housing 23 - High pressure fuel injection pump 24 - Fuel injectors (8) FUEL SYSTEM > LOW PRESSURE FUEL SYSTEM Fuel is pumped from the fuel tank to the primary fuel filter by the electric fuel pump (both located in the fuel conditioning module). Pressurized and filtered, approximately kpa (5-10 psi) during engine idle, the fuel is pumped through the fuel supply line to the secondary fuel filter (the secondary fuel filter housing is located on the front left side of the engine). The filtered fuel leaves the secondary fuel filter and flows to the high pressure pump. The pressure regulator (located in the secondary fuel filter) relieves the pressure, sending some of the fuel back through the fuel return line to the fuel conditioning module and to the fuel tank.

4 Page 4 of 6 Fig 1: Low Pressure Fuel System Courtesy of FORD MOTOR CO. Item Part Number Description 1 - Fuel tank 2 - Fuel supply line from the fuel tank to the fuel conditioning module 3 - Fuel conditioning module 4 - Secondary fuel filter 5 - Fuel flow to the high pressure pump 6 - Fuel flow from the fuel cooler 7 - Fuel return line from the fuel conditioning module to the fuel tank 8 - Fuel pressure regulator 9 - Fuel supply line from the fuel conditioning module to the secondary fuel filter 10 - Fuel return line from the secondary fuel filter to the fuel conditioning module 11 - Check valve 12 - Fuel inlet filter FUEL SYSTEM > HIGH PRESSURE FUEL SYSTEM

5 Page 5 of 6 After the filtered fuel leaves the secondary fuel filter it flows to the high pressure fuel injection pump. The high pressure fuel injection pump is gear driven by the camshaft gear and is located at the rear of the engine. Refer to the ENGINE CONTROL COMPONENTS High Pressure Fuel Injection Pump for fuel pump operation. The high pressure fuel injection pump increases the fuel pressure up to MPa (24,650 psi) and delivers fuel to the fuel rails through 2 high pressure lines, 1 per bank. The system pressure generated by the high pressure fuel injection pump is constantly adjusted by the powertrain control module (PCM) for every operational condition. However, due to the storage volume of the fuel rails, the injection pressure remains constant over the duration of the injection process. Each fuel rail is connected to 4 injectors through individual high pressure pipes. The injectors are controlled by the PCM and are capable of delivering exact fuel quantity based on the operational demands. The fuel injectors are operated in 3 stages: fill stage, main injection stage and end of main injection stage. The fill stage reduces the combustion noise, mechanical load and exhaust emissions. Refer to the FUEL SYSTEM Fuel Injector Operation for additional information on fuel injector operation. The high pressure pump also delivers fuel to the fuel cooler. Refer to ENGINE CONTROL COMPONENTS Fuel Cooler for additional information. Fig 1: High Pressure Fuel System Courtesy of FORD MOTOR CO. Item Part Number Description 1 - Fuel flow from the secondary fuel filter to the high pressure pump 2 - Fuel pressure control valve 3 - Fuel volume control valve 4 - Low pressure fuel flow to the fuel cooler 5 - Fuel return check valve

6 Page 6 of Left bank fuel rail 7 - Right bank fuel rail 8 - High pressure fuel injection pump 9 - High pressure fuel to the fuel rail 10 - Fuel injectors (4 per each bank) 11 - Fuel rail pressure (FRP) sensor

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