Help ! I Put new heads and injectors in my 2005 truck a year ago and have had repeated copper washer sealing problems. I thought it was a milling problem on one of the heads since one injector bore had failed to seal two different times. The truck quit a couple of weeks same way it did before tons of white smoke and then liquid locked with diesel, I told the Ford parts guy that i think something is wrong with one of the heads i bought from him so he agreed get another one under warranty.
So here i go pulling injectors on the head i had problems with and all four had sealed, so I pulled the other four on the other head and found # 5 copper washer gone and o-rings melted. I have read the tsb 7-10-4 and the instruction sheet that came with the head and thought that I had the correct parts but I dont know what to do since both heads have had sealing problems. Also I started out with Carquest injectors until the second failure then had them to get ford injectors,and even the ford injectors i got didn't have new copper washers so i got new ones and put two on each injector on the head that was problematic, and they have sealed for eight months this time instead of weeks. I have tons of questions and no answers.

thanks

 

My OEM reman injector came with a new copper washer in place. Did you make sure to clean out the hold down clamp bolt hole? You have to make sure there are no fluids in them or they will not allow proper seat load on the copper washer. Also make sure you haven't left an old copper washer in the bottom of the injector cup. Its also not a bad idea to clean out the injector cup with a brush, I bought the rotunda injector bore brush set, not sure what others use.

 

These are the bore brushes I bought https://rotunda.spx.com/en-US/Pages/...x?itemID=18739

 

Did you put 2 copper washers per injector on some? It only requires 1 and if that doesn't seal it something is wrong.

 

thanks and have done all your suggestions, i did put two copper washers on the injectors that would only run a couple of weeks and that seemed to have worked. The injectors on the other head have only had one washer, but now that head is doing the same thing that the other side has done. Is their something different about the hold down clamps from a 2005 head vs the new ford replacement heads.

 

Well Only Install 1 copper washer Per Inject

All the Ones you Did 2 Copper washers Need to ALL Have NEW Inject HOLDDIOWNS Installed Now and any others that seal is Bad

Make shure Bolt hole is Clean Blow them Out

Then Install Inject ONLT 1 Copper Washer Per Inject And Torq @ 26ft/lbs

 

thanks but done that twice, i have replaced injectors on other trucks before never had a issue with sealing. Bought this truck to flip and everything that can go wrong has this problem didnt show up till i put new heads from Ford. The injector seal that failed most recently had only sealing washer and had not been distrubed since I put it together about a year ago. This had led me to believe that there was a problem with one of the new heads and had planned to replace that head but now this problem has shown up on the other head and i think it would be unlikely to have two bad heads so something else most be different just dont know what it is

 

Do the Cylinders with New Injectors and Holddowns Still Burn Up Copper Washer????

 

The most recent one did, I would like to find out if the hold downs have been changed and no one knows. My ford guy says 05-07 are the same.

 

Silly question , But did you put any oil on the O-rings?
You don't want to put then on the injector dry. The when you
are ready to put the injector in the head make sure to place
some oil on the O-ring again so it slides in and does not stick
and tear the O-ring. The easy way to clean the bolt holes
is with a wire tube brush with some brake cleaner and then compressed
air to blow it all out
Look at the Single Stem Hand Brushes on this link
http://www.varco.on.ca/IDI-Catalog/A...%20Brushes.pdf
That way you can scrub out any junk. You can also get a set sized for the
cups. Also it's a good idea to make sure that you have the correct hold down
clamps for the heads that you have and that they have not been stretched.
You also may want to check that your torque wrench is not out of whack.
If you have to get an old style beam type of torque wrench.When you do put
it all back together try this. with the beam torque wrench. Run the bolt in
part way then use the beam torque wrench to see how much torque is needed
to tuen the bolt before it reaches the bottom. It should only be a few in/Lb
this number is called prevailing torque**. We are not going to do anything with it
at this time it's just good to know what it is. In this case we just want to find
out if something is gummed up in the threads or not.

Sean


** Prevailing Torque
The torque required to run a nut down a thread on certain types of nuts designed to resist vibration loosening. The resistance can be provided by a plastic insert or a noncircular head.
Glossary of Terminology Related to Nuts and Bolts

 

yes I actually soaked the injector in oil in a small tray i have, the injector bore and the hold down bolt/bolt holes where clean. I have thought that the bolt could bottom out but they dont appear to. I have replaced injectors in other trucks without issues but not this truck.

 

REPEAT INJECTOR DIAGNOSTIC TIPS
http://www.forddoctorsdts.com/techni...orTechTips.pdf


6.0L FUEL INJECTOR INFO
http://www.forddoctorsdts.com/techni...jectorinfo.pdf


COMPRESSION BUBBLE TEST
DTS Articles - Compression Bubble Test
Might be worth this test before Buttoning everything up^^

 

I think i should get all new hold down clamps, but what application my truck is a 2005 but i understand the new heads are the 2007 design and my local dealer says 05-07 are the same.

 

Make shure to use a Deepwell Socket 8mm or 10mm to push that copper washer on the end of the injector In a uniform way




ON EDIT it was a Deep 9MM socket

 

The Injectors are ALL the Same 03-07 The E-series whent till 2010 IIRC

So Holddowns are ALL the Same

The Guide Dowels in the Heads are diffrent is all nothing to do with your Problem