Fuel Conditioning Module Pressure test Recommended Procedure

WARNING: This page is about a different car, the 2009 Ford RV Cutaway, 2009 Ford Econoline, 2009 Ford E450 Super Duty, and 2009 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Restrictions in the fuel line may cause continuous aeration.

Make sure the valve on the Flow Tester, Diesel Fuel 310-193 or equivalent is closed.
Flow Tester, Diesel Fuel 310-193 or equivalent connected.
Using the male and female tool plugs included with the Flow Tester, Diesel Fuel 310-193 or equivalent, plug the fuel return line between the secondary fuel filter and the fuel conditioning module. Plug the fuel conditioning module fuel return inlet port.
Install the Fuel Pump Adapter 310-111 or equivalent with the Gauge 0-1,100 kPa (0-160 psi) Bar (part of DSL ENG Pressure Test Kit 014-00761 or equivalent) between the fuel conditioning module outlet port and the fuel supply line leading to the secondary fuel filter.

Fig 1: Identifying Fuel Pump Adapter 310-111

Courtesy of FORD MOTOR CO.

If the engine starts and does not stall, start the engine and let it idle.
Open the valve on the Flow Tester, Diesel Fuel 310-193 or equivalent.
If the engine is running, run the engine until fuel flows free from cloudiness, gelling (cold weather) or aeration. If the air bubbles can not be purged, check for kinks or leaks.
If the engine does not start, continue to cycle the ignition to the ON position until fuel flows free from cloudiness, gelling (cold weather) or aeration. If the air bubbles can not be purged, check for kinks or leaks. The fuel pump cycles on, then off after 20 seconds.
Verify the battery voltage is greater than 12.5 volts. If the battery voltage drops below 12.5 volts, the battery may need to be charged or there may be a charging system concern, refer to the appropriate Charging System, Symptom Chart to continue diagnosis.
Record the maximum fuel pressure at the fuel conditioning module outlet while the valve on the Flow Tester, Diesel Fuel 310-193 or equivalent is open and fuel is flowing back to the fuel tank.

If the fuel pressure at the fuel conditioning module outlet is below the 344 kPa (50 psi) MIN specification and new primary or secondary fuel filters have not been installed, install new primary and secondary fuel filters. Repeat the Fuel Conditioning Module Pressure test in this section to verify the repair.

If the Fuel Conditioning Module Pressure test has been repeated and the fuel pressure at the fuel conditioning module outlet now meets the 344 kPa (50 psi) MIN specification, remove the fuel return line plugs and connect the fuel return line. Repeat the Fuel System Delivery test in this section to verify the repair.

If the Fuel Conditioning Module Pressure test has been repeated and the fuel pressure at the fuel conditioning module outlet is still below the 344 kPa (50 psi) MIN specification, carry out the Electric Fuel Pump Inlet Restriction test in this section.

If the fuel pressure at the fuel conditioning module outlet is equal to or greater than the 344 kPa (50 psi) MIN specification, carry out the Restricted Secondary Fuel Filter test in this section.