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Call or Text (352) 722-5295Fuel rails on the 2015-2016 Ford 6.7L Powerstroke
The Bosch CP4.2 builds pressure and sends it to two common rails, one per cylinder bank. On this engine, cylinders 1-4 sit on the passenger bank and 5-8 on the driver bank, which is why replacement rails are sold as driver side and passenger side, or left hand and right hand. Rail pressure runs up to 30,000 psi on 2011-2019 engines, and the rails feed eight 19 mm piezo injectors through individual lines. The rail system also includes an electronic pressure regulator (DRV) and a leak rail on the return circuit, and both are sold on their own here. The rest of this engine's parts are on the Powerstroke hub.
What fails and why
The documented threat to the rails is contamination. When the CP4.2's roller followers skate on the cam under low-lubricity fuel, the pump sheds fine metal that passes the metering-valve screen and lands in the injectors, rails, lines, lift pump and tank. After a CP4 failure, the rails have to be replaced or cleaned along with everything else. The other documented problem is on the return circuit: the plastic injector-return fitting can crack with age and leak, and fuel sprayed onto the exhaust in the engine valley is a fire hazard. A diesel smell or fuel on top of the engine are the signs.
Stock replacement vs. upgrade
For most owners this is a stock-replacement job. New rails from XDP or Exergy put the high-pressure side back to factory spec after contamination, and a contamination kit is the one-order route for the whole post-failure repair; check each kit's listing for what is in the box. For the return-side leak, billet replacements for the plastic return fitting are the documented fix, and the Fleece return line repair fitting is built for 2011-2016 trucks. Rail plugs, caps, adapters and T fittings are for custom plumbing work, so match the thread size (M18x1.5 or M14x1.5) to your plan.
What we carry
XDP XD603 driver-side and XD604 passenger-side new fuel rail assemblies. Exergy Performance E05 40150 LH and E05 40151 RH new stock-replacement rails, the E05 40110 leak rail assembly and the E05 40120 electronic pressure regulator (DRV), plus M18x1.5 rail plugs, M18x1.5 to M14x1.5 rail-end adapters, M14x1.5 T fittings, plug-and-nut rail caps, and M12x1.5 to -6AN and -8AN supply fittings. Alliant Power fuel contamination kits AP57001, AP57001NP (no pump) and AP57010 for cab and chassis trucks, and XDP XD515 and XD612 contamination kits. The Fleece Performance Engineering FPE-FMC-FF-RLK-1116 injector return line repair fitting.
Fitment notes
Rails are side specific. Driver side (XD603, Exergy LH) and passenger side (XD604, Exergy RH) are different parts, so order the side you need, or both. The new rails, leak rail and DRV here are listed for 2011-2019, which covers 2015-2016. The contamination kits are listed for 2015-2016 only, with AP57010 as the cab and chassis version. The Fleece return fitting is listed for 2011-2016, so it does not carry over to a 2017 or later truck. When in doubt, verify by VIN.
Frequently asked questions
Can I reuse my fuel rails after a CP4 failure?
Not as they sit. The guidance after a CP4.2 failure is that the rails and lines must be replaced or cleaned along with the injectors, pump, lift pump, filters and tank. If you are installing new injectors, putting them behind a contaminated rail defeats the purpose.
Which rail feeds which cylinders?
The passenger-side rail serves cylinders 1-4 and the driver-side rail serves cylinders 5-8. That matches the part naming here: XDP XD604 and the Exergy RH rail are passenger side, while XDP XD603 and the Exergy LH rail are driver side.
What causes the fuel leak near the rails and injectors?
The documented leak point is the plastic injector-return fitting, which can crack with age. Fuel that sprays onto the exhaust in the engine valley is a fire hazard, so a diesel smell or fuel on top of the engine needs attention right away. Billet replacement fittings are the documented fix, and the Fleece injector return line repair fitting in this collection is made for that spot.
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.