Tech help only please 6.4 split tip injector - Ford Powerstroke Diesel Forum
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Old 04-08-2009, 06:48 PM
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Tech help only please 6.4 split tip injector

Ok first off I am a International tech and this is on a maxxforce7 (aka 6.4 (for the most part)) in a IH CE-200 school bus. This is the first one that we have seen for anything more than an oil change. Anyways it came in for shutting down after about 5 seconds after starting. The oil level is also about 2 inches above full on the dip stick but I cant smell any fuel in it. Hooked up the computer and it had codes 2783 - DPF load above warning level - Active MaxxForce 7 - 2782 - DPF servicing required - Active MaxxForce 7 - 4562 - Cylinder balance below minimum limit - Active. These are IH codes not Ford. Started the bus it was very slow to start and sounded like it was starving for fuel. While monitering the computer I saw the exhaust back pressure rise to almost 60 psi then it would die. I disconnected the exhaust from the back of the turbo. The bus started the same but stayed running there was also extremly heavy white smoke I could bearly see to pull it in the shop. The maxxforce7 will not do the auto injector dissable test or the relative compresion test on servisemaxx so I did a manual cut out test with DLC II both #1 and #2 failed. #1 was much worse on the test. I started a case file with IH. They said to drain the oil to the correct level, replace the #2 injector since it was the one with the code and to drop the DOC and DPF and inspect. The DOC was fine but the DPF was completly clogged. So they said to replace the DPF. I am going to change the oil not just drain as they said to but what do you other techs think of this? Like I said #1 failed worse than #2 why not replace #1 and why only drain to correct level not change? This is my first time with this engine and my dealers first time with it so I would realy thank anyone that would help with this issue. But again please techs only.
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Old 04-08-2009, 06:57 PM
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Here is a bump for you bud. Hopefully you get a tech or 2 to chime in.
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Old 04-09-2009, 05:59 AM
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def change oil. sounds like you might have 2 different injector concerns. have seen a few of these injectors crack externally and leak into the crankcase--causing overfull oil--. have also seen many injectors stick open and fill the exhaust with fuel--causing dpf failure. if the oil is way overfull its going to suck it up through the pcv system and burn it back through the engine. so make sure your intercooler is not full of oil/fuel. it could run away--have seen this too-- i would get fresh oil in it. take off the valve cover and run the engine and look for fuel leaking from injectors. usually leaks from under threaded part where the line threads into injector. sounds like this is your problem. usually when and injector sticks open internally it wont start. will not build enough frp-fuel rail pressure- to start. has to be at 5000 to start..
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Old 04-09-2009, 09:10 AM
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I am not a tech (sorry!), but I stumbled across some info you may find very interesting. The info comes from a school bus forum with the poster having a very similar situation to your own.

To paraphrase the results;

The bus had a bad DOC causing the DPF clogging and also needed new updated programming. A couple of injectors were also replaced. (The damaged injectors may have been a result of constant regen.)

The bad DOC did not properly heat the exhaust gas during regen, resulting in a clogged DPF because of this ineffective active regeneration. Since the regens were ineffective and dpf never cleaned, this lead to near-constant regens, resulting in fuel in oil, and white smoke (which would be the unburnt diesel during regen).

Pay attention to the posts from "Bassman". Page 2 is very interesting.

School Bus Fleet Magazine Forums - Maxxforce DT Emissions Fault light/Fuel in Oil

Again, I'm not a tech, but I thought this might be helpful.
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Old 04-22-2009, 04:45 PM
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Ok so I finally had time to get back to this job. I changed the oil then replaced the #2 injector and dpf. The engine runs smooth but it has a pretty bad knock on the right side. At first I was thinking it was the tick yall always talkabout but it was just to loud to be it. The noise seemed like it was coming from either #1 or #2. IH said to remove the valve cover all of the valve train appears good so I started pulling injectors and glow plugs. All of the injectors look like new but the #1 glow plug has the last 1/2 broken off of it. IH wanted a compression test. #1 showed slightly low so tommorow I get to drop the pan to see if I can see any cylinder damage from the bottom. Also thanks for the replys Im kinda running in the dark on this thing no one at are dealer has any hands on training on this engine.
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Old 04-22-2009, 04:50 PM
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Also kinda unrelated our compression test adapter and gauge was "liberated" by a former emplyee so I had to borrow one from the Ford dealer down the road. While I was there I got to see how yall do the cab off stuff. Now that is how you work on an engine. The tech I talked to was just sittin on the trans workin on the engine. That must be great.
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Old 04-23-2009, 07:31 AM
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What was the compression supposed to be?
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Old 04-23-2009, 02:37 PM
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All cylinders are supposed to be within 10% of each other. Its not a specific # as far as I know.
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Old 06-13-2009, 08:12 PM
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there is a recall from Ford that has to do with injector replacement. I would assume that International engines would also be affected. With Ford you use the VIN and it gives you with injectors are bad on with engine
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Old 11-15-2009, 09:08 AM
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Sounds like pounded injectors, plugged DPF/DOC

Almost every six four I've seen with faggy injectors in it has caused a base engine failure (burnt piston, shortened con rod, etc.)
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