Bad Fuel Injector / Injector Cup - Diesel Forum - TheDieselStop.com
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6.0L Power Stroke Engine and Drivetrain Discussion of the 6.0L Power Stroke diesel engine and drivetrain in the 2003-Up Super Duties and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 6.0L Power Stroke engine.

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Old 04-02-2012, 09:01 AM   #1 (permalink)
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Bad Fuel Injector / Injector Cup

Wife and I went on vacation with our 5th wheel RV. (18K lbs) We had a fuel injector go bad (white smoke, rough idle) The truck limped about 2 miles and completely shut off.
Towed the truck to a Ford dealership and they siad I need :

fuel pump
new fuel injector (#6)
Injector cup

They said because the injector seal blew the injector vibrated and scrathed the cup surface. They said to replace the cup.

My diesel mechanic back home said he rarely to never sees a bad cup and the dealership is milking me.

I told the dealership to install a new (rebuilt) injector (which my mech. said I did not need - the one in my truck could be fixed)

IS IT TRUE THAT A BAD INJECTOR CAN CAUSE THE CUP TO SCRATCH AND CAUSE THE INJECTOR TO FAIL REPEATEDLY?

I have 129K miles. The head gaskets, ARP, EGR delete was installed 5K miles ago. The heads were milled and leak tested. All was OK no problems found
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Old 04-02-2012, 07:47 PM   #2 (permalink)
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Anything is possible i guess. I would do like your buddy says except fixing your own injector. I had those seals blow several times and not once have I had to change the injector cup. If you are worried about it ask them to show you.
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Old 04-27-2012, 03:52 AM   #3 (permalink)
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speedrcr has you covered. Look the cup over carefully. IMO it is very risky doing it w/ the heads on - could put metal in the cylinder.
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Old 04-27-2012, 06:55 AM   #4 (permalink)
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Originally Posted by LisaDupray View Post
Thanks guys, I have the cups, injector o-rings and new valve cover gaskets. I will be installing the cups this weekend. If anyone has any advice or tricks for replacing the cups without removing the heads I would appreciate any ideas. Thanks for all the help any I am sorry for being a green horn diesel tech.
Carl.
One tool that you can use is from Whitaker tools. They offer injector cup replacement tools that can be used in the vehicle. Injector cup replacement is a rare issue, but can be done very easily with the tool from Whitaker. Make sure that when installing new cups to properly clean the injector cup bores before installing the new ones. Also, before driving the new cups in, make sure to seal them with Loctite 609. This is a sleeve retainer which will properly seal the cups.
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Old 04-27-2012, 06:42 PM   #5 (permalink)
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There are videos out on using that tool as well - a search should find them for you.
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