In the an initial of ours “Learning to Diesel” articles, Area Diesel helps a know-nothing newbie change the fuel filter on a 2005 F-250, making use of instructions for any ’03 - ’07 Ford 6.0L Powerstroke engine in Excursions or F250 - F550 trucks.

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First things first. Just want to gain to work? Skip down to the step-by-step instructions: just how to change Fuel filters on ’03 - ’07 Ford 6.0L Powerstroke Engines

Up because that the story behind my first diesel project? check out on.

I’m Joe, a writer who works and plays in the American Midwest. Much to the chagrin of mine old man, I never learned a damn thing around diesels. It’s time i picked increase the skills to work on my very own engine and also save part cash ~ above mechanic bills. That’s why I’m leaning on my friends in ~ Area Diesel service for help on this education series, “Learning to Diesel,” available on the Well Revved blog.

For these articles, I’m partnering v Area Diesel’s Iowa Branch Manager Corey Stallings. He’ll be the brains behind the work, and I’ll be the hapless schmuck testing his patience while he walks me through miscellaneous projects to solve problems, usually improve performance, and also handle straightforward diesel maintenance. Penning the experiences is intended come entertain reader a little bit while you discover to tackle your very own diesel projects. If naught else, this series should help others avoid any type of of the awkward or expensive mistake I’m bound to make.

Alright, off us go.

Learning to change Fuel Filters

When ns asked Corey which task I should take on first, that didn’t take lengthy to respond. “Let"s start with replacing the fuel filters,” that said. “It’s no too facility or intimidating, and it’s an important upkeep to hit at the very least twice a year or every 10,000 miles because that the health and wellness of the fuel system. Getting a handle on this chore have the right to save you some decent money end the next pair of years.” He likewise urged me to salary close attention, because failing to follow the procedure deserve to cause broken or damaged injectors.

Supplies for Replacing Fuel Filters

Before us headed to the garage, my Area Diesel guide sent me shopping. Here’s the list of supplies Corey put on mine list:

Fuel Filter Kit 
NOTE: He encourage using just Motorcraft fuel filters or Racor replacement fuel filters.Paper TowelsBucket or Tub—for draining the fuelCoffee deserve to or other Leak-Proof Container—to deliver the old filter for disposal


To save a couple of bucks appropriate off the bat, ns ordered mine fuel filter kit online, from Area Diesel of course: Racor 6.0L Powerstroke Fuel Filter Kit—Part No. PFF4616.

Required tools for instead of Fuel Filters

Here’s the perform of tools Corey called me to grab:

36mm Socket 6mm Allen Wrench24mm sock or ½" journey RatchetTurkey Baster

Just 4 tools? possibly I can swing this little diesel project after all.

Down to Business

With mine tools and supplies in ~ the ready, i popped the hood and also Corey put me to work.

“Your major fuel filter is located under the driver’s side door, ~ above the frame rail,” Corey said, pointing under the truck.

“The long steel rail the runs the size of the truck, right?” i asked, recalling the days I’d eagerly repeat just around every word mine father claimed while teaching me the simplest of so-called “man’s jobs.”

“Yeah,” Corey answered, not practically as impression by my master of the obvious as I had actually hoped he would certainly be.



“Now, your an additional filter is going to be earlier up right here on the engine, sitting just between the CAC tube and the air intake tube,” he said, phone call my fist to the many prominent—as in the fattest—aluminum tube in the engine. “See the 2 lids there? Those room to keep any extra crap indigenous clogging the filters. You deserve to ignore this enlarge one today; it’s for the oil filter. You desire to remove the smaller lid, the one for the second fuel filter,” the said.

“Got it. Watching you carry out the an initial one should provide me a pretty good feel because that this,” ns told him.

“Yeah, I’m sure it would,” Corey said, laughing as he handed me a hand-written collection of instructions. “But unless you sprung because that ‘practice filters’ , you’re jumping in now, champ. Don’t worry. I’ll be below for backup.”

Fair enough. Ns glanced end the indict he’d composed for me, fumbled approximately for a moment, and also started through the Primary Fuel Filter:

Place the tub or bucket beneath the fuel pump—under the driver’s door top top the structure rail. 
Check. “Hey, look in ~ me mechanic-ing for this reason easily,” ns thought.On the next of the fuel pump, locate the allen plug—the small, brass plug. 2a. Utilizing the 6mm allen wrench, eliminate the allen plug. “Righty tighty; lefty loosey” swam through my mind, choose every various other time I use a wrench.
 2b. Through the record bucket directly in place, drain the fuel / water completely.
 “Woah. For this reason that"s what diesel fuel smells like. Exactly how does everyone huff this?” i wondered.Using the 36mm socket, eliminate the big black finish cap—on the end that’s nearer to the engine. 
Note: The fuel filter will certainly slide out together with the cap.Pull the old filter and the o-ring native the cap, properly disposing of both. 
Note: after ~ draining the filter for a full 24 hours, you deserve to place it in a lidded coffee can or leak-proof plastic bag come safely take it it to a recycling facility that accepts scrap metal.Install the new primary fuel filter into the cap. 
Note: as soon as seated properly in the cap, the brand-new filter will snap right into place. Download the offered o-ring into position top top the end cap.
 “Ha. O-Ring. That sounds a small dirty,” my 14-year-old within voice referred to as out.Insert the brand-new filter and also cap section into the fuel pump, using the 36mm socket come tighten the lid securely—torque to 19lb. Per ft.Being mindful not to end tighten or cross-thread it, reinstall the allen plug—the brass plug removed throughout step 2 above. 
“Do no strip this thread. Do not piece this thread. Do not stri… divine hell! ns just changed a fuel filter,” ns thought.

“So I just replaced a fuel filter v my own two hands, Corey. As soon as do I gain my master mechanic’s certificate?” ns joked.

“Ha. Not just yet, sir. However nicely done,” that said. “Before you an outbreak the champagne, let’s relocate onto the second filter.”

To replace the Secondary Fuel Filter, ns crawled indigenous under the truck and also turned my fist to the engine compartment with Corey’s accuse in hand:

Using the 24mm socket or ½" square drive ratchet, remove the black top cap.Remove the fuel filter indigenous the housing and the o-ring from the lid. 
“O-Ring. Still funny,” i thought, hoping the grownup beside me wouldn’t asking why ns was smirking.Using the turkey baster, drain the overabundance fuel indigenous the housing.
 Note: Again, remember to correctly dispose that the fuel. 
“Yeah, I gain it. Safety and also Mother Earth and also all that,” ns thought.Insert the new secondary filter into the housing.Install the new o-ring top top the lid.Reinstall the black height cap, utilizing the 24mm socket or ½" square journey ratchet come torque the bolt come 124lb. Per in. (or approximately 10 – 11lb. Every ft.). 
“I’m done,” I claimed to myself. “Didn’t also take the long.”

I turn to face Corey. “That it? I currently nailed our first diesel project?” i asked.

“Just about,” the said. “You still have actually one critically necessary task prior to we fire increase the engine. You should remember this every time you replace your filters: after ~ you have both brand-new filters effectively installed, you must prime the fuel system and bleed out any air. To do that, revolve the ignition to the Run position three separate times—for 30 seconds each time.”

Corey provided me a hefty warning: “If friend fail to correctly prime the fuel system, that can cause serious damage to the injectors, and that damage can not be automatically detectable.” He stated damaged injectors deserve to run—seemingly together normal—for a short time after ~ the failure has occurred, therefore it’s not always apparent there’s miscellaneous wrong. I committed the warning to storage for next time and also hopped into the cab to prime the system. A pair of minute later, I started her up.

Victory Lap

While i packed up mine tools and also the dead fuel filters, Corey took a closer look in ~ my work and also then journey a couple of laps approximately the block just to be details the truck wasn’t about to autumn apart. As soon as he gained back, i made my method over for the last verdict. “Alright, man, she’s in an excellent shape,” the said and also handed me a beer. “Here’s to a project well done.” Indeed.

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Look, I’m conscious that in reality, transforming fuel filters simply isn’t all that impressive. Still, I need to admit that beer had actually the extra-satisfying taste that one that’s fine earned. It’s for sure to speak this newbie is looking front to round 2 of our “Learning come Diesel” series.