injector problems, help me figure it out please

[fireguywtc]

I have been having injector problems lately with my 07 in sig. I need some help trying to figure out possible causes. Sorry for the long narrative but I think it’s important for diagnosis

Here’s the backstory: About two weeks ago now I filled up my truck and later that morning I got a “water in fuel” message. I have never had that before but I had not drained it in a while so I drained the HFCM right away and all seemed good to go. A couple of mornings later (the next time I drove it) I started it cold in the morning and it was running rough but it cleared when warm. Well, two mornings later I drove to work and by the time I made it to work it was smoking like a freight train and running rough all the time. Code revealed #5 injector out and had a code for WIF but no message was on the cluster. I had it towed to a shop and a contribution test showed injector 1&5 out. So they were replaced.

Well a week ago Thursday I picked up the truck and drove it to town to see how it was running. Made it about 15 miles and it was running fine but got the WIF message again. Took it back to the shop and they drained both filters, the HFCM had a bit of water in it. All the codes were cleared again. The next day I drove it about 150 miles with no issues. Saturday morning I started the truck cold, again it was running rough but it cleared once warm. Pulled the codes and it gave the code for #1 injector fail (one of the injectors was replaced). Since I was at work all weekend I couldn’t do anything but I left it plugged it to keep it warm, cleared the code, and I drove home Monday with no issues. Monday I changed the oil with Rotella T-6 full synthetic. I waited until Christmas morning when it was cold again to start it and see how it would do. Again, it was running rough and #1 injector code came back.

I also checked the FICM to make sure that it was good. I used Dr. Quads write up on this forum as a guide to check it. The FICM checked out great with 49.5 volts. That of course is with the key on engine off. For giggles I started the truck and at idle it went up to 62-63 volts. Is that normal?

Yesterday my local shop opened back up so I took the truck back to them and will check with them today to see what they find. Just a quick note I got the WIF message again before I left. This is all on the same tank of fuel from when I filled up. The shop is going to drain the tank and fuel system while they have it. At first I was quick to blame the engine for just being crappy but no that I have had all the WIF messages and such, perhaps this is bad fuel? I called the fuel station, they said they are good (of course). I also called the Dept. of Agriculture weights and measures and filed a complaint. They said they will investigate and have 10 days to get the results to me.

My questions: Overall I am not sure if the bad fuel is totally to blame. The fuel filters were drained every time the message came on. Any thoughts on this? Any other ideas of what could be wrong? Could it just be coincidence that this WIF problem happened at the same time as the injectors.

Here are the stats on my truck:

79K miles. EGR delete with ARP head studs, oil cooler replaced, CAT-1 ELC coolant with filter and flush all done 4k miles ago. Blue fuel spring upgrade done about 20k miles ago. Only other problem I have had with this truck is coking on the turbo. I have been very thorough with all maintenance since I have bought the truck new in Feb. 07. If I think of anything else that is pertinent I will add it. Thanks for the help and for reading! Bill

[03powerstrokeuser]

Bill, Something to look for and at. Have your tech check for oem only filters. Next, have him remove the HFCM cap and filter, Shoot the inside filter boss with a crap load of WD- 40. Remove the drain valve, and with a small pick, probe the drain channel. Post back with what he finds. ALSO, save WHAT comes out as you may need it later? Also have him check the upper filter cap, OEM? Have him suction the fuel out of that filter boss and refill it with clean fuel. Winter time demands syn oil in a 6.0, you might want to start using REV-X or ARCHOIL as a preventative measure for the cold weather months. Disconnect / charge and individually load test both batts, and alternator. Bad batts or alt= known FICM killer. 48.5 volts is normal, unless you have the 58 volt mod. Did you also check the FICM cold while cranking? SAVE a fuel sample now, the AG. guys will want it later.Bill

[Mackskibum]

What fuel filter is in the HFCM? OEM or aftermarket? An aftermarket filter will absorb water until its full then pass some through. The OEM are coated to leave the water in the HFCM. What was the temperature? Did you check the HP oil connections? You show SCT livewire- does it do this in stock mode?

[fireguywtc]

Thanks for the replies. Yes all of the filters are OEM brand filters. I do all of the maintenance myself. I did check the FICM with the key on/engine off, cold cranking, and cold running. I forgot to mention that right after I had the work done about 4k miles ago that I had to replace the alternator and both batteries. Alt is a DC 185 high output unit and I checked it to make sure its good. I did not test the batteries, but again they are new and 850 CCA units (bigger then stock).

Though I switched to synthetic oil, I have never had this problem bofore in the last five winters on dino oil. In my opinion I don't think the winters here in central Texas are bad enough to neccesitate major winter preperation. Most lows have been in the 30's and occasionally in the 20's. I will look into the other stuff with my shop.

[fireguywtc]

Looks like it was water in the fuel. Here is a small sample from the tank drain. This doesn't count the rest of the tank, what had been drained prior, and also what it had been running through the engine.

[bismic]

Do you drain the water each time you change the filters?

[fireguywtc]

Yes. There was so much water in there that it had to be from my last fill up

[bismic]

that is a lot! I hate to see that for sure.

[Ford06]

Bismic: Do you drain your tank when you change fuel filters? I have never done that yet.

[Junkers88]

Dang but I hate to sound like a rookie (again) but where is the drain for the fuel and the filter ya'll are talking about. I'm pretty sure mine has never been drained and I'd like to do so.


Thanks folks.

[bismic]

I do drain the water plug every fuel filter change - sometimes more often.

the plug is on the HFCM (frame rail pump/filter) - 6mm hex