Ford 6.0L Power Stroke Diesel :: Injector Spool Valves Blow Off Bodies - Broken Bolts
Aug 6, 2015
While diagnosing a low power and misfire condition on my 04.5, I was measuring coil resistance at the injector connectors. Found 1,3,7 had open circuits for one of the solenoids. 3 bad injector coils and no codes, no contribution codes... Why?
Anyway, pulled it apart to find the spool valves of 1 and 3 came out with the oil log the small bolts that hold them to the bodies had broken off. #7 only 1 bolt had broken off and the other was there but loose.
I got this truck with no history, and Had a variety of issues, like a bad fuse box that caused a no start, massive amounts of water in the fuel, and it had sat for 6 months untouched before I got it. I took care of the previous problems search for my previous posts if interested.
So what caused the spool valve to get blown off the bodies? I'm not sure if these have been rebuilt or ever removed, truck has 135 k. Could it be the water in the fuel that seized the intensifier piston?
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Would it be a good idea to change the injector hold down bolts when I do the injector o-rings? They have never been out at 333,000 miles.
Plan on doing glow plugs, injector wiring, valve cover gasket's, intercooler pipes and the dreaded oil cooler.
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I have been reading here about alternate methods to torquing the hold down bolts for the injectors. This winter I replaced my old stock split shots with new alliant single shots. I installed the injectors into a cold engine and torqued the hold down bolts to 10 ft lbs. I did not ever go back and re-tighten.
Is it suggested to go in and re-tighten the injector hold down bolts to 10 ft-lbs after the engine has been heated up and cooled down? What are some symptoms of a loose injector? I am imagining premature wear on the injector cups, low compression and maybe some mixing of oil into the combustion chamber.
Did just throw the injectors in and go back later to retorque only to find they were all fine or were some loose?
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I wanted to know what happens when the injector hold down bolts are not torqued down to spec, what problems would arise and could it be a reason for somewhat hard starting?
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My truck when idling kind of spools up a little bit for a few seconds and then the turbo goes back down. sounds really cool actually. its been doing it since the truck was new, sounds like a plane engine shutting down. It does it over and over sometimes. I just deleted the dpf and unplugged egr last night and now i can really hear it! is this normal....
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Just bought a 03, the seller showed me a exhaust leak. I found a bolt broken off, flush with the head. Looked at the passenger side when I got home, that side leaks too, and found one broken off bolt there too. Question, are these easy to do? As in, I have extracted broken bolts before, but they where on my V10 and I could just weld nuts to them and they came right out.
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It started after a blue spring upgrade. my turbo would not spool until we revved the engine hard then it kicked in and it's kinda worked since then.. it feels like the truck is struggling on acceleration and the boost builds fast up to 30lbs, the EBP seems to be stuck at 21.48psi until your in 3rd then it jumps and I have power again, also the turbo dumps (farts) if I let off even a little until the EBP jumps then no issues. I replaced the sensor and it's stuck at 21.48 all the time.
Now, I unplug it and it jumps between 26 and 28psi, plug in the old sensor while it's out laying on the motor (not installed) and right back to 21.48. I don't know where to go with this and it's my only truck so I need it running. also it was blowing the intercooler boot off at the turbo during a normal acceleration and the turbo spool has a howl to it when EBP is stuck...
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I have a 2002 F350 7.3L w/superchips programmer, k+n cold air intake. Does NOT smoke a lot from tailpipe
Not running rough since I changed my oil to rotella 5w-40w synthetic.
Appears to have good amount of blow by coming from the oil fill when engine is warm.
Can Bad Injector O Ring(s) cause blow by and oil consumption?
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How do you access the tire air valves on the DRW, the inside tire valve? I can't get my air guage or my compressor air filling connection on the inside tire.
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I filled up at the same fuel station I've filled up at for 6 months, never had a problem. I just bought a 6 liter and put some injector cleaner in on the last fill up. Ever since then, it's been running really rough and missing when cold, and even when it's warm if I really lay into it, it'll pop and sputter. The fuel in water lights been on since I bought it. I think I have a bad sensor, because it was running fine until I put that cleaner in. Since its been running rough I put in new fuel filters and drained the fuel water separator, which only had fuel in it. I don't really know what it could be, but I'm 99% sure it's an injector issue since it started only after I put fuel treatment in.
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I can't get my exhaust manifold bolts off. They are in bad shape. The 10mm is too loose and 3/8 just rounds. I have had the torches on them too! Can the bolts be cut off with a torch?? Haven't broken any. Can't get the bolt heads to move. It's an 04, original manifolds. I am working the driver's side. I can't figure this one out. How to get this manifold off?
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2007 F350... I noticed I have a small power steering leak where the master cylinder bolts onto the hydroboost. Is there a o-ring or seal between the two? or do I have to replace the hydroboost? Been looking online for a schematic but can't seem to find one.
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Went in today and the Service advisor said the oil pan was leaking around the edge of the pan and one of the bolts. He stated he ordered a new oil pan and referred to it as a "new design". I asked him what the "new design" was and he had no idea. Didn't know if it was a metal pan like the newer trucks or if it was another plastic one. Looking for oil pan replacment by Ford and is it the newer metal one or another plastic one ??
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What is the part number for the high pressure oil rail check valves for a 2003 6.0L? I'm referring to the ones that screw into the oil rail. I would like to avoid the local dealer if possible.
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I for the life of me can not even see the bolts to take them off.
2006 F350 4X4
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I've got an injector #7 misfire, so it looks like I'll be replacing my first stick since the warranty expired.
Does the injector from Ford come with the copper crush washer? Will I need to buy anything else except for the oring kit?
where is injector 7? edit: it looks like number 7 is the farthest back on the passenger side. Great! I get to do the hard side.
AE pics below. I've never understood the Power Balance test, it most always looks the same. Seems to me something should look odd with #7, but I'm just not seeing it. As I shut down each cylinder one at a time, all made the engine run noticeably rougher, except it was only a subtle difference when shutting down #7. So that plus the code pointing at #7 lead me to believe that #7 is my culprit.
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I am reviewing the ford assembly instructions before I put my engine back together and noted that it indicates that the balancer bolts are torque to yield. I thought it odd but is it really necessary to replace these? Is it done in practice?
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There are two bosses on back of hpop cover that have bolts holding heat shroud for the exhaust. How difficult are these to remove? The drivers side looks fairly accessible, but passenger side I am not too sure of. I will be back to disassembling everything in a couple of days, and just getting a heads up on it.
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I was driving and my truck started have lack of power, could barely get going on hills, tons of blue smoke (smelled like diesel) real rough idle. I unplugged injectors and found #5 made no difference. I replaced it today and I can't get it to start. It'll get to 2000+ psi 48v ficm, low pressure oil registers, ficm says its in sync. It will crank and blow a lot of black like its half firing or something. It has even crank to, until it tries to fire. From what I've been reading could it be the ficm? That one circuit is fried?
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Occasionally when I'm driving, I'll accelerate and get a brief loss of power, then it'll pick back up, followed by a puff of white/blue smoke. This usually happens when the oil is over 120*, but not quite to full operating temps. It doesn't happen every time either. Only 3 times in the past week. Otherwise, there is a very faint haze of white smoke that seems to be constant. It is very difficult to see unless against a dark background. Oil level is good, I check it once a week, no rising or lowering levels.
I pulled the EGR yesterday, all good, although a tad dirty. Cleaned up no problem. Haven't had a chance to do a bubble test yet. There are some DTCs, but I can't remember off the top of my head what they were. I'm about to go clean the inside of the truck, so I will pull those and update in a few minutes.
Truck has about 148,500 miles.
Torque Pro lists these codes: C1145, P0299, P0677
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Is there a difference between the two harness #'s here besides the first number:
3C3z9d930aa
4C3z9d930aa
Are they the same part? Is one for a different model truck than the other?
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