6.7L Powerstroke High-Pressure Fuel Pump Failure Symptoms

Although the 6.7L Powerstroke engine is more durable, efficient, reliable, and economical than the previous Powerstroke engines, users still have some issues with its high-pressure fuel pump (HPFP). This part is essential to pump the fuel to your car’s injectors and keep the engine running.

So, it’s important to know the 6.7L Powerstroke high-pressure fuel pump failure symptoms before things go out of your hand. Loud noises, engine sputtering during acceleration, bad fuel pressure, starting difficulties, loss of power, and reduced fuel efficiency are some common symptoms of 6.7L Powerstroke high-pressure fuel pump failure.

Let’s dive deep into the details of these symptoms and find out why they occur and how to fix them.

6.7L Powerstroke Diesel High-Pressure Fuel Pump Failure Symptoms

As the symptoms of a faulty fuel pump are similar to some other engine issues, it’s difficult to detect exactly where the problem is. However, there are some clear indications that you should consider and perform a thorough checking of the HPFP and related parts. Some of them include-

1. Loud Squeaks and Noises

This is probably the most obvious symptom of a failing high-pressure fuel pump. When the HPFP fails to perform optimally, it can’t provide enough fuel for lubricating the engine’s inner parts.

Hence, those moving parts make loud sounds to inform you something is wrong. Of course, your car makes many different sounds while you’re driving. But, the high-pitched noises and squeaks coming from a failing HPFP are easily distinguishable from other regular sounds.

The annoying noises often increase when riding on a high road or accelerating the car’s speed. Take your vehicle to an expert if you notice such unusual noises.

2. Sputtering or Jerking Engine

Another common symptom of faulty HPFP is engine sputtering or jerking at high speeds. As you know, the engine can jerk for many other reasons, but here it follows a pattern.

Usually, the jerking or sputtering starts when you increase the vehicle speed, it continues for a certain period (1 to 5 miles), and then it stops suddenly. This happens because the failing fuel pump can’t maintain the optimal pressure needed for smooth performance.

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The up and down of the pressure cause the vehicle to sputter at times, indicating a faulty fuel pump.

3. Difficulty During Acceleration

When you try to accelerate your vehicle, it needs more fuel to increase the speed quickly. However, with a faulty HPFP, the engine doesn’t receive enough fuel to do the job properly. So, the car will take time to increase its speed, or it might not accelerate at all.

If you feel like your car is having trouble during acceleration, check the fuel pump as early as possible.

4. Loss of Power

Under normal circumstances, your fuel pump should perform the same under low or high-stress situations like carrying extra weight, climbing on high roads, or hill areas. But that’s not the case with a damaged fuel pump.

Due to wear and tear, the fuel pump fails to show sufficient resistance as it used to. Hence, your car will keep losing its power and slow down under stress. In extreme cases, the vehicle might lose around 50% of its regular power output.

5. Bad Fuel Pressure

Since the fuel pump is the only part that pushes the fuel to the engine rails, the fuel system will not be able to maintain a decent fuel pressure if the fuel pump is faulty. In such cases, your car’s throttle will fail to respond properly, the car won’t start quickly, and the check engine light will be turned on.

Use a fuel pressure gauge to measure the fuel pressure and check your owner’s manual to see if the pressure is sufficient or not.

6. Problems with Filters

Are your car filters malfunctioning in any way? It could be a sign of a failed fuel pump. Although you have to replace the filters regularly, they don’t require very frequent replacement.

If you notice that the filters aren’t working properly even after regular replacements, get your car to a mechanic and perform a thorough checking of the HPFP.

7. Reduced Fuel Efficiency

You surely know how much fuel your car needs. If you notice that it takes more fuel to reach the same distance, the high-pressure fuel pump isn’t working optimally.

Your fuel pump features a relief valve that controls the mileage to some extent. When the fuel pump is damaged, the valve stops opening, and a large amount of fuel keeps entering the engine without any resistance.

Hence, you need more fuel than regular when your fuel pump fails to perform.

What Causes High-Pressure Fuel Pump Failure?

Besides regular wear and tear, there are multiple reasons why your fuel pump might fail. Lack of maintenance specially oil changes, using low-quality oil, failed sensors, etc., are some common ones. Here are the reasons why most HPFPs malfunction-

1. Lack of Maintenance

I know it sounds like a cliche, but most of the problems with your vehicle are caused by the lack of regular maintenance. Parts of the fuel pump and camshaft lobes are working continuously to keep your fuel system active.

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Regular wear and tear restrict the movement of the piston, and so, the fuel pump fails to maintain sufficient pressure. Typically, the materials of the fuel system are high-quality. But, if you don’t maintain them regularly, they will stop working or lose their efficiency.

2. Leaks in the Fuel Pump

As the fuel pump remains under pressure all the time, leaks are pretty common for the fuel pump and the injectors. For most vehicles, there’s a specific resting pressure that needs to be maintained when the engine isn’t active.

If the pressure exceeds the optimal range, the fuel pump will leak. Things get worse when carbon residue starts to build up. You can use a scan tool to easily detect a leak in the fuel pump.

3. Oil Contamination

Using the wrong oil or contaminated oil is one of the most common reasons why high-pressure fuel pumps fail. Almost all modern vehicles come with a specific oil recommendation provided by the manufacturer.

When you use low-quality oil that’s not compatible with the recommended quality, parts of the fuel system won’t get sufficient lubrication. As a result, there will be more friction, excessive heat damage, and increased wear.

Besides, oil can get easily contaminated by dirt, debris, moisture, and other visible contaminants. Dirty oil also fails to provide enough lubrication for the system. And all these factors eventually lead to fuel pump failure.

4. Failed Sensors

Although failed sensors don’t influence the fuel pump directly, they can indirectly affect it by sending wrong signals to the Powertrain Control Module of your car. The function of the power and temperature sensors is crucial for every successful combustion event.

If the sensors send the wrong readings, the low-pressure mode might be activated for the system. This lack of pressure might harm several parts of the fuel system, causing it to malfunction.

5. Solenoid Failure

In high-pressure fuel pumps, the solenoid usually controls the pressure and volume of the fuel pump. If the solenoid gets damaged, the pressure inside the pump will be lowered, and it will prevent the fuel pump from performing as per the vehicle’s requirements.

How do you check a high pressure fuel pump?

6.7L Powerstroke High-Pressure Fuel Pump Replacement

So, what to do if the 6.7L Powerstroke high-pressure fuel pump of your car fails to provide you with any more service? The best option here is to replace the fuel pump. We would also recommend replacing the related parts like the fuel injectors and fuel lines, but this will cost you a fortune.

Before anything else, you should use a scan tool to make sure the problem is actually in the HPFP. Once you’re sure, take the vehicle to a professional to replace the fuel pump.

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Since the process is complex and time-consuming, we don’t recommend doing it yourself at home. Otherwise, you might end up damaging the internal parts. Here’s a short description of what the mechanic would do to replace the faulty fuel pump-

  • First, he will release the pressure and wait until the engine is completely cool. In your passenger compartment, there’s an access panel placed right above the fuel tank. The mechanic will use the panel to reach the fuel pump.
  • Then, he will remove the return and supply hoses and the EVAP system hoses from the fuel pump. At this point, the fuel pump is ready to be removed.
  • After removing the old pump, the mechanic will attach all the mounting brackets to the new pump and install it in the right place.
  • Finally, he will replace the in-line external filter (if there’s any). All the electrical connections and removed hoses will be reattached, and your car should be ready with a brand-new high-pressure fuel pump.

6.7L Powerstroke High-Pressure Fuel Pump Replacement Cost

Well, the cost will depend on your car model and its manufacturing year or age. In general, the cost range starts from $220, reaching as much as $1062 in some cases. For the parts, you have to pay around $95 to $854, and the labor cost will be anywhere between $124 and $260.

How Often Should You Inspect Or Service High-Pressure Fuel Pump?

To avoid performance concerns, most industry experts recommend cleaning the fuel system once a year. Don’t forget to check vehicle’s owner’s manual for manufacturer suggestions.

We suggest it every 60,000 miles or anytime you detect performance difficulties. A complete fuel system cleaning is not recommended as a preventative service; it is only required when problems arise.

FAQ’s

How long should a high pressure fuel pump last?

It depends on may factors but, As a whole, the fuel pump in your car should last at least 100,000 miles or more.

Can you clean a high-pressure fuel pump?

Yes you can. If your car has an electric fuel pump, a fuel system cleaner can remove sediment accumulation. If you have a manual one (typically in older vehicles), you can open the pump to clean debris from its internal filter. Note: A complete fuel system cleaning is not recommended without experts advise.

Final Words

So, there you have the 6.7L Powerstroke high-pressure fuel pump failure symptoms and causes with solutions. If you’re facing problems like unpleasant noises, engine jerking, power loss, or low fuel pressure, the fuel pump of your car has probably failed. Don’t make any mistake here, take it to an expert as early as possible. Otherwise, there will be more severe issues resulting in expensive repairs

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Brian Polk

Brian is an automotive expert who has 12 years of experience in the industry. He has worked on a variety of cars, from high-end luxury vehicles to budget-friendly options, and has a wealth of knowledge on the subject. He is passionate about automobile and enjoys sharing his knowledge with others, whether they are looking to purchase a new motorized vehicle or simply learn more about the inner workings of these machines. In his free time, Brian enjoys working in his automobile workshop and spending time at the track.

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