Spool valve stuck open?
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Joined: Jul 2011
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Spool valve stuck open?
OK now this is getting ridiculous! 
I replaced the o-rings in my oil rail thinking the #2 injector oil ball cup was leaking. So when I get it all back together (4th time) I still have a massive air leak (new cuss words invented)
I removed the oil rail and upon inspection the #2 injector oil inlet is not full of oil like the other three.
I took the injector out and while I was blowing it out for a detailed inspection I get oil shot back at me from the injector exhaust port (more new cuss words invented, old ones thoroughly over-used). I squirted oil into the high pressure oil inlet and more oil shoots out. I squirted oil into one of the exhaust ports while holding my finger over the other to seal it and oil immediately shoots out of the high pressure oil inlet. I believe the spool valve may be stuck open.
I just wanted to confirm if this is normal before I chew more @$$ for a replacement.
I replaced the o-rings in my oil rail thinking the #2 injector oil ball cup was leaking. So when I get it all back together (4th time) I still have a massive air leak (new cuss words invented)
I removed the oil rail and upon inspection the #2 injector oil inlet is not full of oil like the other three.
I took the injector out and while I was blowing it out for a detailed inspection I get oil shot back at me from the injector exhaust port (more new cuss words invented, old ones thoroughly over-used). I squirted oil into the high pressure oil inlet and more oil shoots out. I squirted oil into one of the exhaust ports while holding my finger over the other to seal it and oil immediately shoots out of the high pressure oil inlet. I believe the spool valve may be stuck open.
I just wanted to confirm if this is normal before I chew more @$$ for a replacement.
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OK now this is getting ridiculous!
I replaced the o-rings in my oil rail thinking the #2 injector oil ball cup was leaking. So when I get it all back together (4th time) I still have a massive air leak (new cuss words invented)
I removed the oil rail and upon inspection the #2 injector oil inlet is not full of oil like the other three.
I took the injector out and while I was blowing it out for a detailed inspection I get oil shot back at me from the injector exhaust port (more new cuss words invented, old ones thoroughly over-used). I squirted oil into the high pressure oil inlet and more oil shoots out. I squirted oil into one of the exhaust ports while holding my finger over the other to seal it and oil immediately shoots out of the high pressure oil inlet. I believe the spool valve may be stuck open.
I just wanted to confirm if this is normal before I chew more @$$ for a replacement.
I replaced the o-rings in my oil rail thinking the #2 injector oil ball cup was leaking. So when I get it all back together (4th time) I still have a massive air leak (new cuss words invented)
I removed the oil rail and upon inspection the #2 injector oil inlet is not full of oil like the other three.
I took the injector out and while I was blowing it out for a detailed inspection I get oil shot back at me from the injector exhaust port (more new cuss words invented, old ones thoroughly over-used). I squirted oil into the high pressure oil inlet and more oil shoots out. I squirted oil into one of the exhaust ports while holding my finger over the other to seal it and oil immediately shoots out of the high pressure oil inlet. I believe the spool valve may be stuck open.
I just wanted to confirm if this is normal before I chew more @$$ for a replacement.
Josh
Hotshot
Joined: Apr 2010
Posts: 19,055
Likes: 235
From: Saratoga Springs,UT
ALL your injectors are New or Rebuilt really Right???
Well the spool valve could be Stuck like Josh is saying
OR
You have a Bad Injector COIL
Or
Bad FICM
OR
BAD FICM wire Harness
Here is a Thread on it cleaning spool valves and I also put in the Info needed to Test Injector Coils with a DVM
https://www.ford-trucks.com/forums/1...cs-inside.html
Well the spool valve could be Stuck like Josh is saying
OR
You have a Bad Injector COIL
Or
Bad FICM
OR
BAD FICM wire Harness
Here is a Thread on it cleaning spool valves and I also put in the Info needed to Test Injector Coils with a DVM
https://www.ford-trucks.com/forums/1...cs-inside.html
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I checked the OHM resistance of both coils and they check out as good. I then tore the injector down. I found and removed a small piece of trash that MAY be the cause of the spool valve sticking. I reassembled the injector, plugged it in and it performed the injector buzz test well. I can visually verify that the spool valve is moving back and forth as each coil is energized.
On a further note, for two reasons I need to know how one could be absolutely certain that the orientation of the spool valve in the injector body is correct. I want to be absolutely sure I have it in correctly even though I re-installed it the way it came out, and I want to check if the rebuilder reassembled the spool valve in reverse during the rebuild process.
On a further note, for two reasons I need to know how one could be absolutely certain that the orientation of the spool valve in the injector body is correct. I want to be absolutely sure I have it in correctly even though I re-installed it the way it came out, and I want to check if the rebuilder reassembled the spool valve in reverse during the rebuild process.
Hotshot
Joined: Apr 2010
Posts: 19,055
Likes: 235
From: Saratoga Springs,UT
Id say if you Found and Removed trash hung up in the Spool Valve your should be good
The Question in my mind is if there is any Trash in the Others
It didnt sound like it from your discription so who knows
This truck shure has been a PIA your probably ready to burn it up LOL
The Question in my mind is if there is any Trash in the Others
It didnt sound like it from your discription so who knows
This truck shure has been a PIA your probably ready to burn it up LOL
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UPDATE The spool valve appears to have been installed backwards during the rebuild process. So much for "each remanufactured injector is tested before it leaves our facility" 
Anyway, I disassembled it again and turned it around in the valve body and reassembled the injector and reinstalled it again (good thing I have a large box of injector washers).
The HPOS now seems sealed and tight. I did another air test and could not keep my hand over the HPOP discharge outlet. When I simply laid the HPOP cover over the HPOP (not bolting it down) the air pressure blew it off of the discharge outlet / IPR portal. This is a very good sign.
A few initial cranks and I was able to achieve 284 pounds on the ICP sensor so I shut the operation down for the night. Tomorrow will tell all.
Anyway, I disassembled it again and turned it around in the valve body and reassembled the injector and reinstalled it again (good thing I have a large box of injector washers).The HPOS now seems sealed and tight. I did another air test and could not keep my hand over the HPOP discharge outlet. When I simply laid the HPOP cover over the HPOP (not bolting it down) the air pressure blew it off of the discharge outlet / IPR portal. This is a very good sign.
A few initial cranks and I was able to achieve 284 pounds on the ICP sensor so I shut the operation down for the night. Tomorrow will tell all.
Hotshot
Joined: Apr 2010
Posts: 19,055
Likes: 235
From: Saratoga Springs,UT
Yes they difinatly Only go in 1 way
It looks to fit either way But only works properly one way if that makes any sense LOL
Wonder if the Close valve coil receives the Longer fat end
It looks to fit either way But only works properly one way if that makes any sense LOL
Wonder if the Close valve coil receives the Longer fat end
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Diesel Care & Performance (DCP) out of Millington, TN
www.dieselcare.net and www.dcpcart.net
Now that I am curious about the company I find out that they are rated "F" by the BBB with five (5) unresolved complaints against them over the last three years. Aparently Billy Williams, the owner, needs to take a closer look at his business and do some house cleaning.
All of that aside, I got her bolted back up about an hour ago and after a few cranks to get fuel to the injectors she fired up with much gusto. Still a little rough at idle from air in the HPOS but she'll be fine. I don't know about Billy Williams, though. I can see his career disipation light glowing a little brighter from all the way down here in Texas. Billy boy, Billy boy, Billy boy....
www.dieselcare.net and www.dcpcart.net
Now that I am curious about the company I find out that they are rated "F" by the BBB with five (5) unresolved complaints against them over the last three years. Aparently Billy Williams, the owner, needs to take a closer look at his business and do some house cleaning.
All of that aside, I got her bolted back up about an hour ago and after a few cranks to get fuel to the injectors she fired up with much gusto. Still a little rough at idle from air in the HPOS but she'll be fine. I don't know about Billy Williams, though. I can see his career disipation light glowing a little brighter from all the way down here in Texas. Billy boy, Billy boy, Billy boy....
Hotshot
Joined: Apr 2010
Posts: 19,055
Likes: 235
From: Saratoga Springs,UT
Man that shure makes it tough to fix when the parts you think your getting should be Good and there Not
I would assume he is useing cheap labor I wont get into that But you know what I mean
At least your Back on the road You shure Earned this one
I would assume he is useing cheap labor I wont get into that But you know what I mean
At least your Back on the road You shure Earned this one
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Don't speak too soon and jinx me now, Benny. J/K 
She starts fine. Runs rough and I can get her up to speed, but she sometimes lags on acceleration, and pulling up to a stop sometimes results in a stall. She starts right back up, though. Sure hoping its just air in the HPOS. If not, the only thing left is the FICM, which will be beaten into submission next week anyway at FICMrepair... just to be certain. Any suggestions on the tune to get? I like the Eco tune a lot, but the Atlas 40 sounds good, too, for my stock truck.
She starts fine. Runs rough and I can get her up to speed, but she sometimes lags on acceleration, and pulling up to a stop sometimes results in a stall. She starts right back up, though. Sure hoping its just air in the HPOS. If not, the only thing left is the FICM, which will be beaten into submission next week anyway at FICMrepair... just to be certain. Any suggestions on the tune to get? I like the Eco tune a lot, but the Atlas 40 sounds good, too, for my stock truck.
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