Fulltext TSBs

Technical Service Bulletins

TSB
05-26-25
  • MISFIRE, LACK OF POWER, BUCK/JERK, EXCESSIVE SMOKE, CRANK/NO START – 6.0L ENGINE – DIAGNOSTICS FOR FUEL SYSTEM – SERVICE TIPS
Publication Date: December 23, 2005

FORD:
2003-2005 Excursion
2003-2006 F-Super Duty
2004-2006 E-Series, F-650, F-750

This article supersedes TSB 04-23-3 to update the vehicle model years and Service Procedure.

ISSUE:

Some 6.0L vehicles may exhibit a misfire, lack of power, buck/jerk, excessive smoke or crank/no start. There are several potential causes for these symptoms.

ACTION:

If normal diagnostics lead to an injector concern, use the following diagnostics to confirm the cause of injector failure and/or to rule out other conditions which may cause the same symptoms as a failed injector.

NOTE:IF DIAGNOSING A LACK OF POWER CONDITION, BE AWARE 2005 MODEL YEAR VEHICLES HAVE A “FORCED LIMITED POWER” STRATEGY WHICH LIMITS INJECTION CONTROL PRESSURE (ICP) WHEN THE FUEL LEVEL IN THE TANK GETS VERY LOW (WELL AFTER THE LOW FUEL LIGHT COMES ON). WHEN THIS OCCURS, DTC P115A WILL BE STORED IN THE POWERTRAIN CONTROL MODULE (PCM).

LOW OR NEGATIVE FUEL PRESSURE

Internal injector damage can be caused by lack of fuel system supply pressure. Restricted fuel filters and/or fuel line(s), or an inoperative fuel pump can create a low or negative fuel supply pressure. Low or negative pressures may hinder the return stroke of the injector intensifier plunger to its rest position, leading to internal injector damage. To diagnose for low or negative fuel pressure and to confirm if any injectors have been damaged:

  1. Perform standard diagnostic procedures including verification of supply fuel pressure while the symptom is evident.
  2. Repair causes for low pressure on the supply side of the fuel system.
  3. Diagnose for failed injector(s) only after rectifying fuel supply pressure.

COMBUSTION GAS ENTERING THE FUEL SYSTEM

Inert combustion gas in an injector can cause a random misfire in one or many cylinders. Combustion gas may leak past the injector’s needle and seat, or the copper combustion seal. Once the combustion gas enters the fuel rail in the cylinder head, it then distributes to other injectors, typically on the same bank. To diagnose for combustion gas entering the fuel system:

  1. Remove outlet fuel lines from the fuel filter housing on top of engine.
  2. Install a balloon over each fuel line with a zip tie.
  3. Disable the fuel pump and FICM relays.
  4. Crank engine and watch for compression pulses in the balloon.
  5. For each line where compression pulses are evident, remove all but one (1) of the glow plugs from the affected cylinder head(s).
  6. Crank engine and watch again for compression pulses.
  7. Remove the glow plug and transfer it to the next cylinder in the head and repeat Step 6.
  8. For each cylinder where compression pulses are evident remove injector(s) and inspect copper gasket and lower O-ring, replace if necessary. If gasket(s) and O-ring(s) are OK replace injector(s). Retest to confirm repair.

Copper Gasket Inspection

  1. Remove the suspect injector and inspect for a missing or damaged copper washer. Review repair history as a missing injector copper washer is most likely caused by improper injector torque at a prior repair for injector replacement. Using an injector, that is not damaged, install a new copper washer and install the injector per Workshop Manual procedure 303-04C and tighten to 33 N-m (24 lb-ft).
  2. Remove injector and inspect copper washer crush pattern. An even circular crush pattern should be visible on sealing surface of copper washer. If the crush pattern is not visible, or not a complete even circular pattern (c shape pattern), the copper injector washer can leak or fail prematurely.
  3. Additional possible causes of damage to the copper washer could be:
    1. Damaged injector hold down.
    2. Hold down bolt stretched from improper torque.
    3. Damaged injector.
    4. Damaged injector cup.

      NOTE:AFTER REPLACEMENT OF ANY FAULTY COMPONENTS – WITH NEW COPPER WASHER REPEAT INJECTOR COPPER WASHER CRUSH TEST TO VERIFY CORRECT CRUSH PATTERN.

ERRATIC HIGH PRESSURE OIL SUPPLY

Erratic supply of high pressure oil to injectors may cause a rough running engine when the engine is HOT ONLY! High pressure oil flow can be disrupted by faulty check valve(s). The check valves dampen the pulsation of the high pressure oil when the injectors fire and if a check valve is damaged those pulsation will affect the other bank causing a miss or random miss fire hot only.

To diagnose, first perform a slow neutral run up in park/neutral. If the engine runs rough and power balance shows a random miss fire between 1500 and 2000 RPM (hot only) proceed to Check Valve Diagnosis.

Check Valve Diagnosis

  1. To isolate the bank with the faulty check valve, disconnect all of the injector electrical connectors on one bank.
  2. Perform a Power Balance test. Engine misfires should be constant on the four disconnected cylinders and the operational cylinders should be contributing evenly.
  3. Repeat Steps 1 and 2 on the opposite bank.
  4. If the operating contribution is erratic on one bank, replace the check valve on that bank.

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage

DEALER CODING

BASIC PART NO.CONDITION CODE
9E52742