Technical Service Bulletins
|Publication Date: October 2, 2003|
|2003-2004 EXCURSION, F SUPER DUTY|
When servicing fuel injectors on the 6.0L Diesel Engine, it is essential that the injectors are reinstalled properly. It has been noted that some Ford Authorized Dealers are installing and/or reinstalling injectors incorrectly resulting in injector failure.
Refer to the following Service Tips, along with the Injector Service Procedure found in the Ford Workshop Manual to assist with performing injector replacement correctly.
INJECTOR INSTALLATION SERVICE TIPS
- Remove/Install injectors with hand tools only. Use of power tools (Air and/or Electric) will damage to the injector and injector O-ring(s).
- Upon removal of an injector, inspect all O-ring(s) to ensure that they are all present and not damaged (i.e. Cut, Gouged, Torn, etc.). If there is a defect on the injector sleeve, replace the sleeve per Workshop Manual Section 303-04D.
- With the injector removed, inspect the injector sleeve for any debris. Remove all debris before the new injector is installed. Utilize special tools 303-D111 and 303-D112 to assist this process.
|NOTE:||IF THE INJECTOR IS GOING TO BE REUSED ALWAYS REPLACE THE O-RINGS AND COPPER GASKET (ONE (1) COPPER COMBUSTION SEAL, TWO (2) FUEL O-RINGS).|
- Utilize a T-40 Torx bit with a minimum shaft length of 2″ to remove and install the injectors. If the Torx bit is too short, it will contact the injector body and may result in damage to the injector, or inadequate torque during installation.
- Prior to installation of the injector, inspect the combustion seal and all O-rings to ensure that they are present, not damaged, or rolled in the injector groove.
- Prior to installing the injector, lubricate the two (2) fuel O-rings with clean diesel engine oil.
- Inspect injector hold down bolt hole in the cylinder head and ensure it is clean and free of any oil or debris that could impact the torque of the bolt, resulting in an improper torque reading. Install the injector and Torque the hold down bolt to 32.5N-m (24 lb-ft). An under torqued injector hold down bolt will result in failure (Figure 1).
- Once the injector has been installed and torqued to specification, fill the top of the injector with clean diesel engine oil. This will aid the installation of the high-pressure oil rail and reduce the risk of damage to the injector O-rings.
|NOTE:||THE 6.0L TORQUE SPECIFICATION IS DIFFERENT THAN THE TORQUE SPECIFICATION USED ON THE 7.3L INJECTORS.|
|NOTE:||CATASTROPHIC ENGINE FAILURE AS A RESULT OF IMPROPER INJECTOR SERVICE IS NOT CONSIDERED A MANUFACTURES DEFECT IN MATERIAL OR WORKMANSHIP, AND MAY NOT BE COVERED BY WARRANTY.|
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OTHER APPLICABLE ARTICLES:
Figure 1 – Article 03-20-10
NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle.
Copyright © 2003 Ford Motor Company