Injector/head question - Ford Powerstroke Diesel Forum
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Old 02-19-2012, 02:00 PM
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Injector/head question

I removed my heads today and on the passenger side 3rd cylinder from the front when I removed the injector it had brown sludge on it and it was also down around the injector seat in the head, all of the other ones were clean. Does anyone know what would be causing this, could it just be as simple as a defective O-ring?
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Old 02-19-2012, 02:17 PM
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pics? that'd be cylinder number #5, you may have been starting to experience a copper washer failure and combustion gas getting up into the cup
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Old 02-19-2012, 03:14 PM
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Are you referring to the copper washer on the end of the injector, if so should I replace all of the washers before re-assembly? I have a new injector seal kit ordered from Tousley Ford.
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Old 02-19-2012, 03:19 PM
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yes, reseal any injector you removed from the head. there are 2 orings and one copper washer on each injector body that need to be replaced anytime the injector is removed.

how does the cup look? if it's burned and can't be cleaned up you may want to think about getting a new cup for that hole too

if you can take pics of what you're talking about so we can be sure.
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Old 02-21-2012, 07:31 PM
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I got my heads resurfaced today and was able to remove the injector cup from cylinder #5 by using a 3/4" pipe tap. I made a tool out of solid plastic by stepping it down on a lathe to match the inside diameters of the cup and it worked perfectly seating the new cup. So far I have the new oil cooler installed, STC upgrade done, head studs in one side, injector cup installed. Tomorrow I am going to start putting the heads on. I am taking lots of pics and will post them when I get this thing back together. One question about installing the heads, should I spray gasket adhesive on them?
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