2008-2010 Ford 6.4L Powerstroke Injection Pumps

Injection pumps on the 2008-2010 Ford 6.4L Powerstroke

The 6.4L Powerstroke uses the Siemens VDO K16, a three-piston rotary high-pressure pump driven off the rear gear train. It feeds one rail per bank at up to 24,650 psi and is credited with about 20 percent more flow than a comparable Bosch CP3. The pressure control valve and volume control valve are built into the pump and are not serviceable separately. The K16 has no internal bypass and relies entirely on fuel lubricity, and it is fed by the electric lift pump in the frame-mounted HFCM at about 24 psi. It is used only on the 6.4L. Parts from the 6.0L's HEUI system and the 6.7L's Bosch CP3 and CP4 pumps do not interchange.

What fails and why

Look upstream for what kills a K16. A plugged water separator drain lets water through to the pump. A failing lift pump starves it and is a listed trigger for failure. Reduced ULSD lubricity is cited as a contributor to wear. When the pump lets go, it sends shrapnel to the injectors and leaves debris lodged in the rails and high-pressure lines, which is why the job always includes a system flush.

Some faults only look like a dead pump. On trucks built before August 20, 2007, the HPFP wiring harness can chafe against the block, ground the volume-control circuit and set P0003, P0004 or P0091 with loss of power or a no-start; TSB 07-26-2 covers it. A drifting fuel rail pressure sensor can set P0087 with a healthy pump.

Replacement vs. conversion

This page is K16 replacement hardware. For a stock truck, the answer is a correct reman K16 installed into a clean system, with the rails and lines replaced or flushed and the supply side fixed so the new pump is not starved or fed water. The stock pump and injectors are adequate below about 700 rwhp. Past that, the documented path is dual K16 pumps with larger injectors. Before any of it, diagnose in order: all codes, fuel filter and lift pump, injector return-flow test, live rail pressure, supply pressure and volume to the HPFP, HPFP output and leak test, then a visual leak inspection.

What we carry

• Pump: the Alliant Power AP63645 remanufactured high-pressure fuel injection pump for the 2008-2010 6.4L.
• Pump kit: the Alliant Power AP63643 reman HPFP kit for the 2008-2010 6.4L.
• Installation: the Alliant Power AP0071 HPFP installation kit for the 2008-2010 6.4L.
• Contamination repair: the XDP XD610 Fuel System Contamination Kit, stock replacement, for the cleanup side of a pump failure.

Check each product page for exactly what the pump kit and installation kit include.

Fitment notes

These parts are listed for the 2008-2010 6.4L Power Stroke in the F-250, F-350 and F-450 Super Duty. On an early 2008 truck, check the build date on the door-jamb label; if it falls before August 20, 2007, have the HPFP harness inspected under TSB 07-26-2 during the job, since a chafed harness can mimic a pump fault. Before you order, look in the HFCM filter bowl. White crystalline residue points to diesel exhaust fluid in the fuel, and if it is there the entire system is condemned, not just the pump. Verify by VIN with the fitment checker.

Frequently asked questions

Can I put a CP3 on my 6.4L?

Nothing on this page converts the 6.4L to a CP3. The K16 and its parts are unique to this engine, and Bosch CP3 and CP4 parts from the 6.7L do not interchange. For builds past roughly 700 rwhp, the documented route is a second K16 with larger injectors.

What else should I replace with a new K16?

Plan on the whole high-pressure system. A failed K16 contaminates the rails, lines and injectors, so the rails and lines get replaced or flushed and the job includes a system flush. Fix whatever starved or watered the old pump too, starting with the lift pump, the separator drain and both filters.

How do I know the pump is actually bad?

Diagnose before you buy. Pull all codes, check the filter and lift pump, run an injector return-flow test, watch live rail pressure, check supply pressure and volume to the pump, then test pump output and leakage. A drifting rail pressure sensor can set P0087 with a healthy pump, and on early 2008 trucks a chafed harness can set P0003, P0004 or P0091.

What kills a K16?

Look at what reaches it from upstream. Water that gets past a plugged separator drain, a failing lift pump that starves it, and the reduced lubricity of ULSD are all cited. Draining the HFCM water separator every one to two weeks and changing both filters on schedule is the single most effective K16 insurance.

Not sure what fits? Call the shop at the number in the header, or use the fitment checker on any product page. We install everything we sell.