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Fuel Injection System

Fuel Injector Replacement Tips

Proper installation of the Ford 6.0L Powerstroke injector is critical for proper engine operation. Improper installation can result in severe engine damage and unecessary warranty claims. GB has determined, based on the analysis of injectors returned as warranty defects, that many injector failures are the result of improper installation procedures or defects in the engine’s fuel delivery system. These types of injector failure are NOT covered under GB’s limited warranty.

A missing copper washer or improperly torqued injector can allow hot combustion gases into the injector cavity. This will result in failure of the lower fuel o-ring on the injector causing fuel leakage into the combustion chamber when the engine is turned off and hot combustion gases into the fuel system when the engine is running.

Fuel leakage into the combustion chamber can result in hydro-static engine lock-up and engine failure. This will occur when the engine is shut off and the fuel drains past the injectors tip into the combustion chamber.

Combustion gases leaked into the fuel system will result in siezure of the fuel injector’s internal components and multiple injector failure. Since all of the injectors share a common fuel rail within the cylinder head a combustion leak into the fuel system will contaminate all of the injectors.

Black soot on the bottom of the injector is a clear indicator that the injector was improperly torqued or the copper washer was missing.

Improper alignment of the oil rail ball tubes during installation can result in damage to the high pressure o-ring resulting in oil leakage. Often this occurs after installation and an extended period of operation, rather than immediately after installation. Ensure ball tubes are free from damage or “grooving” on the ball valve stem. If grooving or other damage is present the oil rail should be replaced.

Fuel contaminated with water, air or debris can cause injector tip failure resulting in sever engine damage. Fuel is used to cushion the needle in the nozzle. The lack of fuel at the nozzle, caused by air in the system, low fuel pressure or no fuel pressure can result in this type of failure. Water lacks the characteristics of diesel fuel for lubricity, viscosity and specific gravity. Water present in the fuel can result in fracturing of the nozzle tip.

Installation Tips – Be Sure:

  • Copper washer is present on injector being REPLACED.
  • Copper washer is present on REPLACEMENT injector.
  • Ensure ball tubes are free from grooving, nicks, burrs or other damage.
  • Oil rail ball tubes are centered and properly aligned.
  • Injector is properly torqued – see service manual.
  • Engine oil is clean and at the proper level.
  • Fuel supply is free from water, air and contamination.
  • Fuel pressure is at the manufacturers recommendation.
  • Injector sleeve is clean and damage-free.
  • Engine coolant shows no sign of engine oil (sleeve failure).
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