6.7 Powerstroke Fuel Filter Change Problems & Solutions – A Complete Guide

The most common 6.7 Powerstroke fuel filter change problems include

  • Difficulty removing the old filter, fuel leaks
  • Reduced engine performance, check engine light illuminating, air in the fuel system, etc.

These problems can be aggravating and costly, but they are also avoidable. You can keep your 6.7 Powerstroke running well by understanding the recommended maintenance schedule and potential concerns.

Continue reading to learn the problems that can arise from changing your fuel filter, how to prevent them, and how often to change your fuel filters, including the cost.

6.7 Powerstroke Fuel Filter Change Problems and Solutions

The table below shows the overall picture of fuel filter change problems.

1Difficulty removing old filterRust or corrosion on the filter housing
2Leaking fuelDamaged O-ring or improper installation
3Air in the fuel systemImproper bleeding of the air from the system
4Reduced engine performanceClogged or damaged fuel filter
5Check engine lightProblems with the fuel system or engine

Here are the 6.7 liter powerstroke engine fuel filter change problems in detail.

#1 – Difficulty Removing The Old Filter

One of the most typical issues encountered while changing the fuel filter on a 6.7 Powerstroke engine is difficulty removing the old filter. Various variables can affect this, including:

  • The filter being over-tightened when you last changed it.
  • The filter being corroded or rusted.
  • The filter wrench is either the wrong size or is being used incorrectly.


To troubleshoot this issue, use a different size fuel filter wrench. Penetrate oil to release any corrosion or rust that keeps the filter in place.

#2 – Leaking Fuel

Leaking fuel is another issue that might develop after a fuel filter change. Various variables can contribute to this, including:

  • The new filter is not installed correctly.
  • The replacement filter’s O-ring is not properly placed.
  • The fuel filter housing is not securely fastened.


To troubleshoot this issue, ensure that the replacement filter is placed correctly and that the O-ring is securely seated. You should also ensure that the fuel filter housing is fastened correctly to increase your 6.7 Powerstroke fuel mileage.

#3 – Air In The Fuel System

Another problem that might occur during a fuel filter change is air entering the fuel system. Various variables can cause this, including:

  • The fuel filter was not correctly set before installation.
  • The fuel filter is not properly tightened.
  • The fuel system leak.


Ensure the fuel filter is correctly set and tightened to troubleshoot this issue. In addition, inspect the fuel system for leaks and repair any that you detect.

#4 – Reduced Engine Performance

If you notice decreased engine performance after changing the fuel filter, it could be due to a clogged filter or a fuel system problem.


To troubleshoot this issue, inspect the fuel filter to ensure it is not clogged. If the filter appears in good condition, you should check the fuel system for any other problems, such as a leak or clogged fuel injector.

If none of these problems exist, the problem may be with the engine itself. You should take the vehicle to a mechanic to find out if your engine is one of the 6.7 Powerstroke years to avoid.

#5 – Check Engine Light

If the check engine light illuminates after replacing the fuel filter, it could be due to a fault with the fuel system. This could result from a leak, blocked fuel injectors, or an issue with the fuel filter itself.


To troubleshoot this issue, inspect the fuel system for any problems and repair them as necessary. Taking professional treatment is recommended.

How To Avoid Fuel Filter Change Problems?

Here are ways to avoid having fuel filter change problems in the first place.

● Properly preparing the fuel system before changing the filter

Prepare the fuel system properly before installation. It is one of the most critical measures in avoiding fuel filter change difficulties.

This includes filling the fuel tank halfway and running the engine until it reaches normal operating temperature. This will help keep air out of the fuel system while changing the filter.

● Using the correct type of filter for the specific engine

Another critical step in avoiding fuel filter change issues is using the correct filter. Not all filters are made equal, and utilizing the incorrect type of filter might result in clogging or leaking. It is critical to consult the owner’s manual or a mechanic to confirm that you are using the correct filter for your engine.

● Following the correct procedure for bleeding the air out of the fuel system

To ensure that the engine runs smoothly after changing the fuel filter, bleed the air out of the fuel system. The approach for bleeding the air out of the fuel system differs depending on the engine. So consult the manufacturer’s handbook or a professional to ensure that you follow the correct procedure.

By following these, you may avoid typical fuel filter change issues and keep your engine running smoothly and effectively.

How Often To Change Fuel Filter On 6.7 Powerstroke?

Generally, you should replace the fuel filters every 15,000 miles or 12 months, whichever comes first. This replacement frequency depends on several parameters, including the type of driving done and the fuel quality used.

If you use your vehicle for heavy-duty tasks like towing or lifting heavy weights, you may have to replace the fuel filter more frequently.

6.7 Powerstroke Fuel Filter Change Cost

On average, a fuel filter change on a 6.7 Powerstroke engine will cost between $90 and $210 (inclusive of parts and labor). This cost depends on several factors, including the repair shop’s location and the replacement fuel filter’s cost.

Here is a table showing a breakdown of all the necessary costs.

ServiceAverage Cost
Fuel filter replacement (including parts and labor)$90 – $210
Fuel filter$15 – $50
Fuel filter wrench$15 – $40

Additional repairs may increase the cost of changing the fuel filter on a 6.7 Powerstroke engine. As a result, it is critical to get the car evaluated by a mechanic to ensure that no other faults require attention.


Here are more related questions you might be interested in.

How many fuel filters does a 6.7 diesel have?

There are two fuel filters on the 6.7 Powerstroke diesel engine. The primary fuel filter is in the engine valley, while the secondary fuel filter is on the frame rail.

Can I use a cleaner to clean my fuel filter?

Yes, you can, but cleaning a fuel filter is not recommended. Several specialized cleaners can remove pollutants from the filter media. However, replacing the fuel filter when it becomes clogged is often more effective.

Is it possible to upgrade my 6.7 Powerstroke engine?

Yes, you can upgrade your 6.7 Powerstroke engine with various aftermarket components designed to improve its longevity and performance. Upgrades may include enhanced oil coolers, EGR deletion kits, and larger injectors.

Key Takeaways:

Changing the fuel filter on a 6.7 Powerstroke engine is easy, but problems may arise. Hence, understanding these 6.7 Powerstroke fuel filter change problems and how to troubleshoot them will ensure a smooth fuel filter change and a healthy engine. Here are a few key takeaways.

  • A 6.7 Powerstroke engine’s fuel filter should be replaced every 15,000 miles or 12 months, or more frequently if the vehicle is utilized for heavy-duty labor or in a dusty area.
  • The cost of replacing the fuel filter on a 6.7 Powerstroke engine might vary but anticipate paying between $50 and $150 on average.
  • The removal of the old filter, leaks, and air in the fuel system are all common issues with 6.7 Powerstroke fuel filter replacements.
  • Changing the fuel filter regularly and treating any faults as soon as they arise will prevent more costly repairs and ensure maximum engine efficiency.

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