Installing a regulated return fixes the 99 thru 03 Ford Powerstroke dead head fuel rail issue

Ford produced a few award-winning diesel truck designs between 1999 and 2003 that, for the most part, featured general improvements to the Powerstrokes. However, in Ford’s attempt to reduce fuel tank emissions by preventing heated fuel in the fuel rails from flowing back into the fuel tank, they created a whole new problem. This is a common problem on Ford Powerstrokes, known as a “deadhead” by diesel enthusiasts, which gets its name from the process of feeding fuel into the head of the fuel rail.

Each injector gets its fuel from the head of the fuel rail, unfortunately this “rail” has no outlet and is ultimately starred by the fuel injectors. Lack of fuel in the injectors causes them to work inefficiently and increases noise. Fuel held in the rail can also get hot because it no longer flows, causing more noise and wear on the injector. Ford tried various solutions, but the problem persisted until the 6.0 Powerstroke diesel engine was introduced in 2004.

Ford Diesels from 1999 to 2003 were and still are wildly popular trucks. This means that there are many people suffering from “dead” fuel system problems. These problems can lead to poor mileage, loss of power, and noisy operation. Many of the affected trucks may also have a noticeable knock at idle. Engines that make a knocking sound also often experience a loss of power combined with poor fuel economy. These symptoms are caused by air entering the fuel system and becoming trapped there.

Trying to convert this type of engine to VO to solve dead head is not really a proper solution. Because fuel is stagnant in the fuel rails, any fuel left in the rails must be consumed to make room for incoming fuel to displace it. So if you’re running on diesel and want to switch the engine to VO, you need to run the engine long enough to use up the fuel in the rails before any VO is burned. This is actually a bigger problem when switching from VO to diesel because the engine will need to run for 15 minutes or more on diesel before it can be safely shut down.

The fuel rail crossover or regulated return is a much better solution and was created specifically to solve the “dead” fuel rail problem found on 99-03 Powerstroke engines. The Fuel Rail Crossover, (FRx), connects the two heads and allows air to return another way instead of forcing it through the injectors, preventing them from doing their job efficiently. This product was designed as a true bolt-on system that eliminates repairs that require the need to cut the return line and use compression fittings. The FRx is also machined to provide as low as 72 psi depending on the type of spring used in the installation, which is perfect for OE parts or performance upgraded parts. This fuel rail crossover system completely eliminates air in the fuel system, which in turn provides a smoother ride, quieter idle, less noise, better throttle response and longer engine life. fuel injectors. It’s also a fraction of the price compared to other regulated return systems that do the same thing, making it a no-brainer.

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