Low fuel pressure can kill injectors.

6.0 POWERSTROKE INJECTORS TIPS

INJECTOR REMOVAL
Injector removal requires valve cover removal Valve cover gasket is reusable

INJECTOR WIRES

INJECTOR WIRES
Injector wires pass through aluminum rocker arm carrier Make sure to position connectors so you can reinstall retaining clips easily

INJECTORS
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

INJECTORS
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

RETAINING CLIPS

Retaining clip

Retaining clips were installed at nine O'clock position Easier removal and installation if moved to 12 Oclock

INJECTORS

Located between valves under valve cover

INJECTOR WAVEFORM

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
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 heads 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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