03 6.0 injector stuck open? How to know which one. - Ford Powerstroke Diesel Forum
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Old 03-02-2011, 04:25 AM
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03 6.0 injector stuck open? How to know which one.

I am working on this great 03 6.0 550 for its yearly major malfunction. Last year I had to replace the FICM and 5 injectors. I had to replace a few injectors a couple of times due to getting bad reman injectors. So I had been running find for about the last year until it died the other day going down the road.

The truck will restart after after a little bit and run fine for 10-30 seconds before it losses injectors one by one until it dies. I have changed both fuel filter thinking it might be running out of fuel but no change. I checked the oil and it smells strong of diesel and seams to be a little thin. Some times when you go to start it, the starter can't turn the motor over. You have to hit it a bunch of times until it can finally turn over. It is not dead batteries or a bad starter. It is hydro-locked. The whole truck jerks a little when it tries to start it.

So my assumption is that there is an injector stuck open leaking fuel into the engine or something is cracked ect. The reason for it slowly dieing is compression gasses are getting forced into the rail.

So how would be the best way to find the problem area? Balloon test? Does it sound more like a stuck injector or something cracked or broken?

This is a sanding/plow truck for a company I do work for. I have there only other sander truck her also, 06 550 6.0, it has a broken flex plate I have to replace today. At least the flex plate i know how to fix.
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Old 03-02-2011, 06:16 AM
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the baloon test will let you know if your getting exhaust gasses into the fuel, but to perform a contribution test you'll need some software such as auto enginuity.
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Old 03-02-2011, 08:04 AM
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definetly sounds like your getting combustion back into the fuel. failed injector copper ring most likely. balloon test would be your best bet on finding the source injector.
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Old 03-02-2011, 08:37 AM
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Once I get the other junk for out I will try that. The copper o-ring would not cause it to leak fuel into the engine though, unless it took out the rubber o-ring. Well that will be the job for tomorrow or the next day.

Trying to get the flexplate put in the other truck, but the transfer case will not come undone from the trans. Steel dowels and aluminum components in never a good idea. PIA
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