4 Fix To 6.7 Powerstroke Fuel Rail Pressure Sensor Problems

On a 6.7 Powerstroke, a fuel rail pressure sensor is found near the middle of its fuel rail. It receives information about the fuel pressure and transfers it to the ECU for analysis. 

The pressure sensor usually goes wrong due to problems like a bad fuel line, a defective fuel pump, a faulty sensor, etc. As a result, you will face problems like the check engine light being on, poor acceleration, stalling, etc.

When this sensor fails, the ECU does not receive fuel pressure information, and thus cannot control the amount of fuel injected into the engine.

Don’t panic if you also face these problems. In this article, you will get solutions to the possible pressure sensor problems and be able to fix them.

What Causes 6.7 Powerstroke Fuel Rail Pressure Sensor Problems?

The fuel rail pressure sensor generally causes disturbance when the sensor gets faulty itself. It can also malfunction if other components of the fuel system, like the fuel line or pump, get damaged. Common causes of fuel rail pressure sensor on the 6.7 Powerstroke can be:

  • Bad fuel lines 
  • Defective fuel pump 
  • Damaged fuel tank 
  • Faulty pressure sensor 

4 Easy Solutions For 6.7 Powerstroke Fuel Rail Pressure Sensor Problem 

To locate where the problem has occurred, you will need to run a test first. Make sure the engine is turned off at least two to three hours ago and cool enough to touch. 

If you find the sensor is faulty then replacing it will solve the problem. Follow the steps below to fix the fuel rail pressure sensor problem on your 6.7 Powerstroke.

Testing Pressure Sensor

You can test it to be sure that your sensor is faulty. Firstly, do a visual inspection. Check if there is any dirt, rust, or visual damage on the sensor. After that, test the sensor with a multimeter to check if there is any internal damage. For this:

  • Unplug the fuel rail and turn the ignition switch of the vehicle on.
  • Set the multimeter in voltage parameter
  • Now take the black wire of the multimeter to the sensor’s negative lead.
  • Connect the red one to the positive wire.
  • Now see the voltage that appeared on the display.

If the reading matches the ideal voltage range, then it’s OK. Otherwise, be sure that the pressure sensor has gone bad. If the fuel sensor is working properly, check other components to see if they are functioning properly.

1. Faulty Pressure Sensor: Replace It

Usually, the problem occurs in the fuel rail pressure sensor. It can be due to electrical issues or any other issue. Cleaning the dirt sometimes solves the problem, but most of the time the sensor is faulty inside. In this case, you will need to remove the old sensor and replace it with a new one. To do this:

  • Park your 6.7 Powerstroke on a flat surface. Keep it in 1st gear.
  • Unplug the negative cable of your vehicle’s battery to avoid electronegativity
  • Remove the engine cover
  • Now remove the air intake to get to the old sensor
  • Then find the fuel rail and its test port. To depressurize it, put a drip pan under the test port. Using a flat head screwdriver, depressurize it. Don’t forget to put on goggles and proper cloth during this process.
  • Take off the electrical harness and detach mounting hardware from the sensor. Now remove it from the fuel rail
  • Clean the harness and fuel rail before mounting the new sensor
  • Install the new pressure sensor and tighten the mounting hardware with screws
  • Reattach the electrical harness with the new pressure sensor and place the air intake in its place.
  • Put on the engine cover and reconnect the negative cable to the battery. 
  • Now take your 6.7 Powerstroke to a test drive
  • If the replacement of the pressure sensor is successful, the vehicle should run properly and the check engine light would go off 

The cost of a new fuel rail sensor is around $50-$150. About the labor rate, it should be between $150-$250. 

2. Bad Fuel Lines: Fix It!

Fuel rail pressure sensors can also not work properly if the fuel flow is restricted on fuel lines. A clogged filter can be responsible for less fuel flow. Clean the filter properly to get rid of any dirt clogging it. 

The best way of cleaning a fuel line is to pass compressed air through the line. There is a filter that takes fuel. If it is broken or damaged, the line can get clogged. Repair it.

3. Defective Fuel Pump: Repair It

The fuel rail pressure sensor is suited to work properly under normal conditions. If the fuel pump is defective or weak, the system will crash and the sensor will not work. Do the necessary repairs or replacements if your fuel pump is faulty.

4. Damaged Fuel Tank: Clean and Check for Leakage 

Any type of damage to the fuel tank can cause the pressure sensor to fail. Check if the tank is leaking or if there is any debris there. Repair the leaking point. Also, clean the tank to let the fuel flow continue. To clean the fuel tank:

  • Empty the fuel tank by collecting fuel in a proper container
  • Clean any rust or dirt found on the top of the tank
  • Clean the interior of the tank with a mixture of soap and water
  • Stir the cleaning mixture inside the tank
  • Then dry it with a lint cloth or air compressor
  • Also, inspect the tank for any damage or leakage. If found, replace it.

FAQs

Fixing a bad fuel rail pressure sensor can seem a daunting task if you are relatively new to technical work. There can be various questions in your mind regarding this process. Below we tried to answer some of them.

What Are The Symptoms Of A Bad Fuel Rail Pressure Sensor?

When the fuel rail pressure sensor gets bad, you will notice the following symptoms on your 6.7 Powerstroke:

  • Check engine light turned on
  • Vehicle starts with difficulty 
  • Engine stalling 
  • Poor acceleration
  • Bad gas mileage 

What Codes May You See If The Fuel Rail Pressure Sensor Gets Bad?

DTC codes that appear on OBD-II equipped vehicles due to fuel pressure sensor problems are P0190, P0191, P0192, and P0193. Here P means problem in powertrain, 0 is generic code, and 1 means fault in emission management of fuel.

Can You Clean A Fuel Rail Sensor?

Sometimes you may need to clean the sensor. The sensor may get covered with dirt or debris which can block the terminals and cause the sensor to not work. In this case, use a soft brush or clean cloth to wipe off the dirt from the sensor.

Should You Drive With A Bad Fuel Rail Pressure Sensor?

You can drive your vehicle that has a bad fuel rail pressure sensor if the problem is not so severe. But regular use with a bad sensor can make the problem worse. The engine will fail to receive the proper amount of fuel which will worsen the engine’s performance.

Does Bad Fuel Rail Pressure Sensor Cause High Pressure On The Fuel Rail?

A damaged fuel rail sensor cannot control the ideal air-fuel ratio. It can cause excess or low fuel supply to the engine. As a result, there can be high pressure on the fuel rail.

Conclusion

To avoid this type of fuel sensor problem, you can purchase a fuel injection maintenance kit. It comes with cleaners to clean the sensor and other injector parts like the fuel pump and fuel line. 

Keeping the fuel system clean would lessen the chance of its getting bad frequently. Whenever doing any part replacement on the engine, make sure to disconnect the battery. Otherwise, you may get an electrical shock.

Lastly, replacing sensors saves you money but it requires some technical knowledge. If you are completely new to this type of work, it will be better to take the help of a mechanic and learn the process.

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