A minimum 45 psi of fuel pressure is necessary at all times (including WOT) to maximize engine performance and ensure proper injection operation. Fuel pressure can be measured via a test port on the fuel filter housing (details below).
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• Disconnect both negative battery cables.
• Remove the air filter assembly and cold-side intercooler tube to improve access to the side of the fuel filter housing.
• Remove the fuel filter cap and fuel filter element. Completely drain the fuel filter housing with a turkey baster, syringe, or similar means.
• Remove the fuel pressure regulator cover using a T-27 torx driver (4 bolts). Maintain light pressure against the bottom of the cover as the spring tension will have a tendency to push it outwards and you don't want to accidentally lose any parts. The fuel line connected to the regulator cover does not need to be removed unless it is also being replaced.
• The lower regulator cover bolts can be difficult to access because of the position of the radiator hose. We use a short T-27 torx bit designed to slip into a 1/4" nut driver. The bit can be inserted into the head of the bolt and rotated with a 1/4" wrench (see image for details). This eliminates the need to remove or pull on the upper radiator hose.
• Blue spring upgrade kits are provided by various manufacturers, including Ford Motor Company and International. A minimal kit will include a new spring and regulator cover gasket. More elaborate kits may include additional parts which should be removed and replaced as necessary. The kit we are installing includes the parts pictured.
• Carefully retrieve the spring, spring seat, and cover gasket. Play in the fuel line will allow the cover to be pulled out of the way to provide ample room.
• Install the new components in reverse order. Lightly coat the cover gasket and spring seat o-ring with clean motor oil before installing.
• Reinstall the fuel regulator cover to the fuel filter housing, being cautious not to pinch the gasket. Do no overtighten the bolts, the aluminum threads will strip easy; tighten just enough to seat the cover gasket completely.
• Install a new fuel filter element and fuel filter cap o-ring (coat o-ring in clean motor oil before installing). Torque filter cap to 14 N-m (10 ft-lbs).
• Reconnect both negative battery cables.
• Cycle the key into the "run" position three times for at least 10 seconds per cycle (once you hear the fuel pump turn off, turn the key to "off" position and back to the "run" position). This will fill the fuel filter housing and prime the fuel system.
• Start the engine and verify that there are no leaks. You may wish to test fuel pressure, the procedures of which can be found here: 6.0L Power Stroke fuel pressure test procedures