Fuel supply system

Fuel Supply System Features Fuel Supply System Features

• The fuel supply system uses a new Horizontal Fuel
Conditioning Module (HFCM). The HFCM filters fuel, • Horizontal Fuel Conditioning Module (HFCM)
separates water, senses water, and recirculates warm
fuel through the pump during cool fuel conditions. • (1) Chassis Mounted 10 Micron Fuel Filter
• The 6.4L Power Stroke Diesel also uses 2 fuel
®

filters and a stand alone fuel cooler system. • (1) Engine Mounted 4 Micron Fuel Filter
• Water Separator
• Fuel Cooler

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 fuel supply system

FUEL FLOW

Engine Fuel Flow

• After the fuel is filtered it is routed to the Internal Transfer Pump (ITP).
• The fuel pump, located in the Horizontal Fuel
Conditioning Module (HFCM), draws fuel from the • The ITP is located inside the high pressure fuel injection pump
fuel tank and through a 10 micron fuel filter. and is used to increase the fuel pressure supplied to the high
pressure fuel injection pump’s three (3) internal pistons.
• The HFCM contains the fuel pump, filter, water
separator, water in fuel switch, fuel drain, and • After the fuel is pressurized it is routed to the high pressure fuel
diesel thermo recirculation valve (DTRM). rails and to the fuel injectors via high pressure fuel supply tubes.
• The DTRM controls the flow of fuel returned from the engine • A Pressure Control Valve (PCV) located in the outlet side
mounted filter through the HFCM. If the fuel being drawn from of the high pressure fuel injection pump controls the fuel
the fuel tank is cooler than a specified temperature then return pressure by dumping excess fuel into the fuel return line.
fuel from the engine is recirculated into the inlet of the pump.
• A Fuel Rail Pressure (FRP) sensor located in the
• After the fuel is conditioned by the HFCM, the clean pressurized right side fuel rail monitors the fuel pressure.
fuel is sent to the engine mounted fuel filter assembly where
particles larger than 4 micron are filtered out of the fuel. • Return fuel from the injectors is routed through a drilled passage
from each cylinder head where it is then united with return fuel
• The engine mounted fuel filter assembly also regulates fuel from the high pressure fuel injection pump before being sent
pressure by releasing excess pressure via a return fuel line to the fuel cooler and back to the engine mounted fuel filter.
back to the HFCM. The engine mounted fuel filter also contains
air bleed orifices to remove air and return it to the tank.
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 fuel supply system
HFCM (Horizontal Fuel Conditioning Module)
• The HFCM is mounted to the frame rail on the drivers side.
• The HFCM is a single module that performs multiple
tasks. It separates water from the fuel, senses
when water is present in the fuel, filters particulates
from the fuel, and creates the fuel flow needed to
supply fuel to the engine mounted fuel filter.
• A DTRM (Diesel Thermo Recirculation Module)
is also part of the HFCM. It recirculates fuel that
returns from the engine mounted fuel filter back
into the fuel filter instead of back to the tank.

Fuel Pump
Power
Drain Valve

Water In Fuel Sensor

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Fuel Cap Fuel Filter Fuel Pump
HFCM Components
• The HFCM is composed of six (6) main components:
- Housing
- Fuel Filter (10 micron)
- Fuel Cap

- Electric Fuel Pump

- Manifold (contains the fuel inlet check valve) DTRM

Fuel Inlet
- Diesel Thermo Recirculation Module (DTRM) Check Valve
is also part of the HFCM. It recirculates fuel that
returns from the engine mounted fuel filter back
into the fuel filter instead of back to the tank.

Manifold
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Fuel Return Fuel Return Directed via DTRM Fuel Return
HFCM Fuel Flow
to Tank to Tank or Back Through Pump to HFCM
• Fuel is drawn into the HFCM from the fuel tank via a
supply line.
• Fuel enters the filter housing via a one-way check valve.
• Once in the filter housing, water is separated from
the fuel. If large amounts of water are found in the
fuel, a sensor in the separator warns the operator of
this condition by illuminating a light on the dash. Pump
• Fuel is then drawn through the 10 micron Outlet
fuel filter and into the fuel pump.
• Conditioned pressurized fuel is then supplied to the engine
mounted fuel filter via a fuel supply line. The pump has
an internal regulator that limits fuel pressure to 24psi.
• Fuel returning from the pressure regulator on the engine
mounted fuel filter comes into the HFCM and a DTRM
either allows the fuel to return to the tank or returns it
to the unfiltered side of the fuel filter in the HFCM. The
DTRM starts to open (recirculating fuel back into the Fuel Supply
To Filter/Pump Fuel Supply
pump) at 80°F (27°C) and is fully open at 50°F (10°C). to HFCM
(suction side) to Engine
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 fuel fuel
supply system
supply system

Engine Mounted Fuel Filter

• An engine mounted fuel filter is mounted
Filter Cap
to the intake manifold.
• The engine mounted fuel filter is a 4
micron cartridge style filter.
• It also incorporates a fuel pressure regulator
Engine Mounted (in the standpipe) and an air bleed. Fuel from
the regulator is returned to the HFCM.
Fuel Filter
NOTE: Please exercise extreme cleanliness
when servicing the fuel filter.

Filter Housing

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Fuel Pressure
Fuel Pressure Regulator
Regulator Located
Inside Standpipe • The fuel pressure regulator is located inside the
Assembly engine mounted fuel filter housing in the standpipe.
• It regulates fuel pressure by routing unfiltered
Fuel Supply fuel from the filter housing to the HFCM via
a spring loaded poppet style valve.
• The cracking pressure (pressure at which the valve
Filtered Fuel Fuel Return begins to open) of the valve is 2psi +\- 0.5psi. Actual
Outlet from Cooler fuel pressure may be above or below this specification.
• The regulated pressure of the valve is
3psi+/- 0.5psi. Actual fuel pressure may
be above or below this specification.
NOTE: The fuel pressure regulator is NOT serviceable
separate from the housing! If the regulator needs to be
replaced, then the entire housing must be replaced.

Fuel Temperature
Sensor (FTS) Fuel Return to Tank
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Fuel Return Banjo Fittings

• The fuel return lines (located on the front of
each cylinder head) utilize a banjo bolt to route
the return fuel back to the fuel system.
NOTE: The 6.0L Power Stroke® Diesel utilized a banjo
bolt with a check valve inside. Do not interchange the 6.0L
banjo bolt with the 6.4L banjo bolt.
NOTE: The 6.4L Power Stroke Diesel uses an open banjo
bolt with no check valve. The check valves are no longer
Fuel Return Banjo Bolt needed since the drilled passages in the cylinder heads are
now utilized as fuel return passages.

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