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Call or Text (352) 722-5295The fuel rail system on the 2020-2022 Ford 6.7L Powerstroke
The 6.7L Powerstroke uses two fuel rails fed by the Bosch CP4.2 high-pressure pump, and together they supply all eight injectors. For the 2020 third-generation engine, Ford raised injection pressure to as much as 36,000 psi, up from 30,000 psi, and fitted new 8-hole piezo injectors that can fire up to eight times per stroke. The rails hold that pressure for the injectors, and a fuel pressure sensor reads it.
What fails and why
Ford recall 24S78 (NHTSA 24V957000) covers 2020-2022 Super Duty diesels because biodiesel deposits can form on the CP4.2's roller components and cause pump failure. When a CP4 fails it can contaminate the whole fuel system, and both rails are on the replacement list along with all eight injectors and the high-pressure and return lines. The warning signs are rail pressure codes P0087, P0088 and P0191, rough idle, stalling and metal flakes in the fuel filters. Metal in a filter means stop driving and diagnose before more debris reaches the injectors.
Sensor, fittings or full kit
Match the part to the problem. A rail pressure code alone does not prove the sensor is bad, because those codes are how pump trouble first shows up, so check the filters for metal before you replace the fuel pressure sensor. If the filters are clean and diagnosis points to the sensor, it is a single part. If you find metal, the whole high-pressure side is involved and a contamination kit is the right purchase. The rail plugs, rail ends and fittings are for custom fuel plumbing, such as setups that add a CP3.
What we carry
Alliant Power AP63647 fuel pressure sensor (FPS), listed for 2020-2025 trucks, plus the Alliant AP57003 fuel contamination kit and the AP57003NP version without the pump. XDP MFG XD599 stock-replacement contamination kit and the XD614 without the pump. Exergy Performance rail hardware: an M18x1.5 rail plug, an M18x1.5 rail end to M14x1.5 adapter, an M14x1.5 three-way T, an M14x1.5 plug and nut rail cap, and M12x1.5 to -6AN and -8AN high-flow CP3 supply fittings.
Fitment notes
The contamination kits are listed for 2020-2022 trucks only, matching the third-gen system and its all-new injectors; they are not listed for 2017-2019. The Alliant Power fuel pressure sensor carries a 2020-2025 listing. Exergy thread sizes are in each title, so match M18x1.5, M14x1.5 or M12x1.5 to the port you are working on. Pickups and chassis cabs share this engine; confirm your truck with the fitment checker on the product page and verify by VIN.
Frequently asked questions
Does a P0087 or P0088 code mean my fuel pressure sensor is bad?
Not necessarily. On the 2020-2022 6.7L, rail pressure codes P0087, P0088 and P0191 are the first electronic sign of CP4 pump trouble. Pull the fuel filters and look for metal before you replace the sensor, and if you see metal flakes, stop driving the truck.
Do the fuel rails need replacing after a CP4 failure?
Yes. Both rails are on the CP4-failure replacement list along with all eight injectors and the high-pressure and return lines. The Alliant Power and XDP contamination kits are listed for that repair on 2020-2022 trucks; check each listing for its exact contents.
What are the Exergy rail plugs and fittings for?
They are plumbing pieces for custom fuel setups, sized by thread: an M18x1.5 rail plug and rail end adapter, M14x1.5 tees and caps, and M12x1.5 to AN supply fittings for a CP3. If you are planning that kind of build, call the shop and we will help you map out the parts.
Not sure what fits? Call the shop in Wildwood, FL at the number in the header, or use the fitment checker on any product page. We install everything we sell.