Defective OEM injectors - was "Compression leak..."
ADDED INFORMATION - It turns out that the defective injector caused a deformation of the injector cup (nipple cup). It is now at the Ford dealership that sold us the defective injector, awaiting Ford's field service engineer inspection. I have posted a separate thread about defective OEM injectors. NOTE - I am not suggesting that folks not use the OEM remanufactured injectors, only that they inspect them CAREFULLY prior to installing them. As explained more fully in the other thread, the dealership's techs are seeing some number of these OEM reman'ed injectors that are defective right out of the box.
ORIGINAL INFO - simply for reference:
Here's the situation - sorry it's so long, but I'm trying to cover everything:
The truck is a 2006 F250 6.0 (4WD), 150K miles, stock and the oil cooler and EGR cooler were replaced prior to failure at about 120K. Regular maintenance with Motorcraft filters and T6 5W40. I have and use a ScanGauge 2 (more on that further down). Had been running fine but did a slightly early (2700 miles) oil change before trip and drove about 50-75 miles before trip with no signs of any issues. The only thing that happened prior to the main issues was a slight rough idle or stumble once at a lunch stop about 100 miles into the trip. Tapped the fuel pedal and it went away and then ran fine on the interstate until about 300 miles into the 400 mile Christmas trip, when it began to run rough.
The Scangauge 2 showed a P0281 code pending (no Check Engine Light), so I pulled into the next stop and started checking things out. I noticed that I had spilled a little oil on the valve cover and the #7 injector connector had a little oil on it, so I disconnected it, cleaned it with some electrical contact cleaner and reconnected it. The truck started right up and seemed to run fine. We made it to my in-laws with me thinking I had found the problem.
Nope. The next morning, I went to start the truck and it ran BADLY - it fired right up and the Scangauge showed good HPOP pressure, FICM at 48v, etc., but it was smoking, idling rough, running rough, etc. and showed p0281 pending again (still no CEL).
I went to the nearest Ford dealer and got a couple of sets of injector o-rings and crush washer kits, a new standpipe and dummy plug, and just in case, a new injector. Got the valve covers off, the oil rail out, etc. and the injector pulled (the copper crush washer came up still attached). I didn't see anything obvious, and in fact, everything looked really good, but I went ahead and put the new injector in, along with the new standpipe and dummy plug. Put it all back together, and after the expected couple of crank cycles to clear the air out of the system, it fired up. Now it was running worse, with what sounded like a seal leak at the combustion washer - a sort of air pump "puff, puff" sound at compression. It was there even when using the starter wire (i.e., no start cranking). I was 99.99% I had not screwed anything up, but ???
I went back in, pulled the new injector and examined it - the washer looked uniformly "crushed," but on closer inspection, it appeared there was a leak between the injector "face" and the washer. Sure enough, the "rebuilt" injector had all sorts of visible pits on the face, and you could trace the leaks on the underside of the washer and face of the injector. So I took it back to the dealer, who agreed it didn't look right. We looked at two more injectors with the same date code (12/2/13) and all looked iffy, with one having visible signs of carbon fouling still remaining. The manager got one with a earlier date code and it was installed. Also of note was yet another injector of the same date code had one of the two electrical connections at the spool valve which was not even connected to the injector.
However, the first new / reman'ed injector not sealing properly caused a deformation in the injector cup, and therefore, an injector cannot seal/seat properly and seal - see above update.