6.0 POWERSTROKE INJECTORS TIPS

Low fuel pressure can kill injectors.
6.0 POWERSTROKE INJECTORS TIPS
INJECTOR REMOVAL
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Injector removal
requires valve cover
removal
Valve cover gasket is
reusable
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INJECTOR WIRES
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INJECTOR WIRES
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Injector wires pass
through aluminum
rocker arm carrier
Make sure to position
connectors so you can
reinstall retaining clips
easily
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INJECTORS
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Generation 2 Siemens injectors
Top fed with oil
Oil is fed to injector through oil rail
Top of injector has a O-ring to seal oil rail to injector
O-ring can be damaged and cause high pressure oil leak
Injector O- ring leak will result in misfire
Injector reseal kits are now available if you damage O-ring
Fuel enters toward bottom
Has two coils to open and close injectors
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INJECTORS
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Injectors operated by fuel control module
Use 48 volt pulse
4 wires to run spool valve both directions
Spool valve has two position – one position allows oil into injector
Other spool valve position shuts oil off and drains excess oil back to
crankcase
Injectors use high pressure oil to activate
C clip at top of injector breaks causing O ring to get cut and high
pressure oil leaks out causing no start
Injectors have a weep hole that tend to leak fuel into oil
Oil level gets full of diesel and wipes out turbo bushings
Replace all injectors
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RETAINING CLIPS
Retaining clip
Retaining clips were installed at nine O'clock position
Easier removal and installation if moved to 12 O’clock
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INJECTORS
Located between valves under valve cover
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INJECTOR WAVEFORM
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MEASURE VOLTAGE
40.17
VOLTS
.78
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INJECTOR POWER
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NEW INJECTORS
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#40 TORX BIT LONG NEEDED TO REMOVE INJECTOR
HOLD DOWN BOLTS
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INJECTORS
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Injector removal – As
you loosen torx bolt the
hold down forces
injector out of bore
making removal easier
During installation
torque injector a little
beyond spec and make
multiple passes
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INJECTOR O-RING TESTCompression leak into fuel system test
´ Injector O-ring test- Disable fuel system
´ Remove outlet lines at fuel filter housing install
balloons over line ends
´ Crank engine and see if you get pulses in
balloon
´ This will show you what side the injector leak is
on
´ Remove glow plugs one at a time on effected
head until compression pulses stop
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BAD O RING FUEL SIDE OF THINGS
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Engine oil dilution –Possible damage to Turbo
Suspect bad injectorDrain engine oil and leave oil drain plug out
Unhook one fuel outlet line at fuel filter housing
Plug hole at housing and energize fuel pump
Watch for fuel coming out of oil pan
If that head passes hook up other head’s injector line
and watch for fuel from oil pan
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OHM CHECK INJECTOR
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INJECTOR RESISTANCE
The two open and other 2 close wires have the same resistance.
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INJECTORS
Lack of fuel can internally damage injectors
´ Lack of fuel hinders return stroke of
intensifier piston to rest position
´ Early 2003 injectors had a high failure rate
´ Mid way through 2003 injectors were
internally redesigned with a different clevis
which improved lateral support of the
plunger also reduced injector scuffing
´ Injector plunger use a DLC (Diamond like
coating) helps reduce scuffing
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INJECTORS
Cold start running problem has been an
injector issue usually clears up in less than one
minute
´ Reflashes available to help in cold start running
problems
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INJECTOR DIAGNOSTIC
IDS Ford lap top scan tool can perform a
cylinder power balance graph
´ Power balance graph can help pick out bad
injectors
´ Mass fuel desired test
´ Relative compression test
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