Melted away copper washer effect on injectors - Ford Powerstroke Diesel Forum
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post #1 of 5 Old 06-10-2013, 05:20 PM Thread Starter
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Melted away copper washer effect on injectors

*Can a mod move this to the problem forum I posted in the wrong one. Thanks

Hey guys,

I had a copper injector melt away from not enough torque on the injector hold down and lifting. The hot exhaust gases got past the tip and heated/coated the injector body with suit and melted the orings. This injector has less than a year on it and after replacing the orings and washer It idled fine for about 8 mins then still get a misfire/contribution on the cylinder that it went out on.

Is it possible the continuous exposure to the high exhaust heat has ruin the internals of the injector?

I did a buzz test before I pulled it and the injector barley made noise. After I cleaned and reinstalled it buzzed the same as the rest of the injectors. It also passed the ohms test. Could it be the pintle section of the injector is messed up from high heat?

Last edited by makaveli200369; 06-10-2013 at 05:39 PM.
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post #2 of 5 Old 06-10-2013, 07:18 PM
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Originally Posted by makaveli200369 View Post
*Can a mod move this to the problem forum I posted in the wrong one. Thanks

Hey guys,

I had a copper injector melt away from not enough torque on the injector hold down and lifting. The hot exhaust gases got past the tip and heated/coated the injector body with suit and melted the orings. This injector has less than a year on it and after replacing the orings and washer It idled fine for about 8 mins then still get a misfire/contribution on the cylinder that it went out on.

Is it possible the continuous exposure to the high exhaust heat has ruin the internals of the injector?

I did a buzz test before I pulled it and the injector barley made noise. After I cleaned and reinstalled it buzzed the same as the rest of the injectors. It also passed the ohms test. Could it be the pintle section of the injector is messed up from high heat?
****ty shop did this down the road. On buddy truck replaced 1 injector and it took out injector cup needed a new head! Just wanted to let you know

Ryan
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post #3 of 5 Old 06-10-2013, 08:28 PM Thread Starter
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I hope I don't need a new head...at the worse I hope I only need to replace the injector cup. I'm about to swap the injector between cylinder 3 and 7 and see if the misfire moves with the injector.
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post #4 of 5 Old 06-11-2013, 07:41 AM Thread Starter
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So I switched the injectors from #7 and #3 and the misfire followed the injector to #3. This was newer injector...so a blown copper washer letting hot gasses come in contact with injector body can ruin it. Make sure you torque down those injector hold downs to the new ford spec!

Last edited by makaveli200369; 06-11-2013 at 07:53 AM.
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post #5 of 5 Old 06-13-2013, 06:15 AM
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I don't know if everything is original on your truck but if the heads have ever been changed, you could have a mismatch with your hold downs. If you look at the "hump" in the cylinder head that is drilled & tapped for the hold down, if the hole is centered, it should have the hold down with the rounded back. If the hole is off center, it should have the hold down with the squared back.
An injector hold down with a rounded back will (sometimes) not seat the injector properly in a cylinder head with an off centered hole. The problem is that it doesn't always happen but when it does, it will drive you crazy because it isn't always the case. If in doubt, the hold downs with the squared back are universal and will work in either head.
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