Technical Service Bulletin: Ford Powerstroke 6.0 L – Fuel Injector Combustion Seal – Installation Procedure
Reference Number(s): 03-20-10, Date of Issue: October 13, 2003
|FORD:||2003-2004 EXCURSION, F SUPER DUTY|
DRIVEABILITY – FUEL SYSTEM – INJECTOR COMBUSTION SEAL – INSTALLATION PROCEDURE – SERVICE TIP – 6.0L ENGINE
ENGINE – FUEL SYSTEM – INJECTOR COMBUSTION SEAL – INSTALLATION PROCEDURE – SERVICE TIP – 6.0L ENGINE
When servicing fuel injectors on the 6.0L Diesel Engine, it is essential that the injectors are reinstalled properly. It has been noted that some Ford Authorized Dealers are installing and/or reinstalling injectors incorrectly resulting in injector failure.
Refer to the following Service Tips, along with the Injector Service Procedure found in the Ford Workshop Manual to assist with performing injector replacement correctly.
INJECTOR INSTALLATION SERVICE TIPS
- Remove/Install injectors with hand tools only. Use of power tools (Air and/or Electric) will damage to the injector and injector O-ring(s).
- Upon removal of an injector, inspect all O-ring(s) to ensure that they are all present and not damaged (i.e. Cut, Gouged, Torn, etc.). If there is a defect on the injector sleeve, replace the sleeve per Workshop Manual Section 303-04D.
NOTE: IF THE INJECTOR IS GOING TO BE REUSED ALWAYS REPLACE THE O-RINGS AND COPPER GASKET (ONE (1) COPPER COMBUSTION SEAL, TWO (2) FUEL O-RINGS).
- With the injector removed, inspect the injector sleeve for any debris. Remove all debris before the new injector is installed. Utilize special tools 303-D111 and 303-D112 to assist this process.
- Utilize a T-40 Torx bit with a minimum shaft length of 2″ to remove and install the injectors. If the Torx bit is too short, it will contact the injector body and may result in damage to the injector, or inadequate torque during installation.
- Prior to fuel injector installation, inspect the combustion seal and all O-rings to ensure that they are present, not damaged, or rolled in the injector groove.
- Prior to the fuel injector installation, lubricate the two (2) fuel O-rings with clean diesel engine oil.
- Inspect injector hold down bolt hole in the cylinder head and ensure it is clean and free of any oil or debris that could impact the torque of the bolt, resulting in an improper torque reading. Install the injector and Torque the hold down bolt to 32.5N.m (24 ft-lb). An under torqued injector hold down bolt will result in failure.
NOTE: THE 6.0L TORQUE SPECIFICATION IS DIFFERENT THAN THE TORQUE SPECIFICATION USED ON THE 7.3L INJECTORS.
- Once the injector has been installed and torqued to specification, fill the top of the injector with clean diesel engine oil. This will aid the installation of the high-pressure oil rail and reduce the risk of damage to the injector O-rings.
NOTE: CATASTROPHIC ENGINE FAILURE AS A RESULT OF IMPROPER INJECTOR SERVICE IS NOT CONSIDERED A MANUFACTURES DEFECT IN MATERIAL OR WORKMANSHIP, AND MAY NOT BE COVERED BY WARRANTY.
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