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Operating Instructions
High Pressure System Air Pressure Test contd.
6. Apply shop air pressure to the right-side high pressure oil rail:
2003 – 2004-1/2 Vehicles: Use adapter No. 551581; apply air pressure through the fill port.
2004-1/2 – 2007 Vehicles: Use adapter No. 511671; apply air pressure through the ICP port. Note: It may
be possible to use adapter No. 511671 on 2008—newer 6.0L Econoline vans.
7. Use a mechanic's stethoscope (OTC No. 4491 or equivalent) to check for leaks. Repair leaks, if necessary,
and repeat air pressure test. If leaks are still detected, continue with diagnostics.
8. Disconnect shop air supply. Install an ICP sensor or plug.
9. Apply shop air pressure to the left-side high pressure oil rail:
2003 – 2004-1/2 Vehicles: Use adapter No. 551581; apply air pressure through the fill port.
2004-1/2 – 2007 Vehicles: Use adapter No. 511671; apply air pressure through the ICP port. Note: It may
be possible to use adapter No. 511671 on 2008—newer 6.0L Econoline vans.
10. Use a diagnostic tool (OTC No. 6764 or equivalent) to open the IPR valve and allow the oil to drain. An
air leak should be heard. Close the IPR valve.
11. Use a mechanic's stethoscope (OTC No. 4491 or equivalent) to check for high pressure oil rail leaks.
Repair leaks, if necessary, and repeat air pressure test.
If no audible leaks are detected, proceed to the High Pressure Oil Pump test procedure.
High Pressure Oil Pump Test
CAUTION: To prevent equipment damage,
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Do not over-tighten the high-pressure tube assembly fitting.
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Do not leave the IPR valve energized longer than 120 seconds at a time.
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Inspect adapter o-rings before performing these tests. Replace o-rings if worn, cracked, or cut.
1. Verify the ICP sensor or fill port plug is installed.
2. Remove the high pressure pump cover.
3. Remove the M12 plug from the top of the high pressure pump.
4. Install adapter No. 511671 on top of the high pressure pump in place of the plug removed in Step 3.
5. Apply shop air pressure to the high pressure pump through the adapter.
6. Use a diagnostic tool (OTC No. 6764 or equivalent) to close the IPR valve.
7. Check the high pressure pump for leaks.
8. Inspect the discharge tube, quick connect joint, and the high pressure oil branch tube for damage.
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If the leak is isolated to the branch tube quick connect fitting, install a new quick connect fitting and a new
branch tube.
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If no leaks are found, and the engine has the correct oil flow, install a new high pressure pump.
Form No. 551980, Sheet 1 of 1, Back
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