Leaky Injector from Copper Washer?
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3rd Gear
Joined: Dec 2022
Posts: 3
Likes: 1
From: Huntington Beach CA
Leaky Injector from Copper Washer?
I just replaced all my injectors on my 1984 f250 with a 6.9 idi. Before and after replacing the injectors, orings, lines, and washers I had a leak that seemed to be coming from the base of injector #2. When starting after sitting for a few hours it would fire up right away than after a second or two it would start to idle rough so I would rev it a little and eventually it goes back to idling normal. I've pulled the injector and replaced the cap, o-rings and the lines and nothing fixes the problem. I pulled the new injectors after running them with the leak for a day and compared one that wasn't leaking to the one that was leaking. The one that was leaking was a lot darker around the base of the injector than the one that wasn't leaking. I think the fuel is getting around the washer somehow. Does anyone know a fix to this?
Fleet Mechanic
Joined: Sep 2016
Posts: 1,519
Likes: 224
From: Nevada
This sound to me that maybe you didn`t get the hole cleaned out the Injector screws into.
The flat base the Copper Washer sits on needs to be clean and flat. If there is some debris
in there, you are getting blow by past the washer, that is why the end of the Injector is dark
colored.
You are not getting a fuel leak, it is leaking from the compression stroke when the fuel is sprayed
into the Pre Cup then onto the Piston, and it fires. We are talking something like 22:5 to 1
compression. The Injector sprays the fuel around 1800 PSI.
The Copper washers are a one time use. I have read they can be heated cherry red to anneal
them, so they can be used again...never done it.
Rereading through this, did you remove all 8 Injectors?
Changing "O" Rings, Caps etc.... won`t fix the problem.
I read some guys use a Steel Bore brush for cleaning guns to clean out the hole.
There is a Ford Reamer tool to clean out the base. A bit pricey.
I found one on E-Bay.
https://www.ebay.com/itm/23376000398...Bk9SR_Kn_q-oYQ
I picked up one a several months ago for $110 and free shipping.
Search the part #, the price is all over the place. Might find it cheaper.
Charlie
The flat base the Copper Washer sits on needs to be clean and flat. If there is some debris
in there, you are getting blow by past the washer, that is why the end of the Injector is dark
colored.
You are not getting a fuel leak, it is leaking from the compression stroke when the fuel is sprayed
into the Pre Cup then onto the Piston, and it fires. We are talking something like 22:5 to 1
compression. The Injector sprays the fuel around 1800 PSI.
The Copper washers are a one time use. I have read they can be heated cherry red to anneal
them, so they can be used again...never done it.
Rereading through this, did you remove all 8 Injectors?
Changing "O" Rings, Caps etc.... won`t fix the problem.
I read some guys use a Steel Bore brush for cleaning guns to clean out the hole.
There is a Ford Reamer tool to clean out the base. A bit pricey.
I found one on E-Bay.
https://www.ebay.com/itm/23376000398...Bk9SR_Kn_q-oYQ
I picked up one a several months ago for $110 and free shipping.
Search the part #, the price is all over the place. Might find it cheaper.
Charlie
Fleet Mechanic
Joined: Sep 2016
Posts: 1,519
Likes: 224
From: Nevada
I would not either, just threw it out there
as I have read it several places on the forums.
I did a lot of Google searching for the IDI Copper
washers. Seems they are next to impossible to find
unless a new return kit is ordered.
I found this for the sizes for the IDI Engine
.615 OD = 15.621MM
.298 ID + 7.569MM
.058 Thick + 1.4732MM
I did find that the copper washers for the 98 - 02 Dodge Cummins sizes
15mm OD
7MM ID
1.5MM Thick
I ordered 3 packages of the Dodge washers (only 6 to a package)
I don`t have any IDI spare Washers on hand to compare yet.
Guess I could pull an Injector out of one of my spare Engines to see a difference.
of course the used IDI washer could be some what deformed. IDK yet.
The 3 packages came to $21.66
If they don`t work, guess I`ll need to buy a Cummins so I can use them....JK....JK
I checked on McMaster-Carr and didn`t find the proper sizes.
Iam just throwing this out here what I found.
www.russrepair.com said he has them in stock for the IDI.
Charlie
as I have read it several places on the forums.
I did a lot of Google searching for the IDI Copper
washers. Seems they are next to impossible to find
unless a new return kit is ordered.
I found this for the sizes for the IDI Engine
.615 OD = 15.621MM
.298 ID + 7.569MM
.058 Thick + 1.4732MM
I did find that the copper washers for the 98 - 02 Dodge Cummins sizes
15mm OD
7MM ID
1.5MM Thick
I ordered 3 packages of the Dodge washers (only 6 to a package)
I don`t have any IDI spare Washers on hand to compare yet.
Guess I could pull an Injector out of one of my spare Engines to see a difference.
of course the used IDI washer could be some what deformed. IDK yet.
The 3 packages came to $21.66
If they don`t work, guess I`ll need to buy a Cummins so I can use them....JK....JK
I checked on McMaster-Carr and didn`t find the proper sizes.
Iam just throwing this out here what I found.
www.russrepair.com said he has them in stock for the IDI.
Charlie
Thread Starter
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3rd Gear
Joined: Dec 2022
Posts: 3
Likes: 1
From: Huntington Beach CA
Update leak fixed!
I never reused any copper washers. I had tried cleaning out the injector seat first with a brush and some rags and that didn’t work. So I ordered a reaming set and that worked perfectly. No more leak and great seal.
I got the reaming kit off Amazon seemed to be universal and it was only $40. Worked good just might need to remove fuel lines to get it lined up straight.
I got the reaming kit off Amazon seemed to be universal and it was only $40. Worked good just might need to remove fuel lines to get it lined up straight.
8milelake 17Pcs Diesel Injector Seat Cutter Cleaner Universal Injector Re-Face Reamer Tool Set
More Turbo
Joined: Dec 2021
Posts: 554
Likes: 186
Thanks for letting us know how you fixed it 👍
A lot of people seem to forget about doing so after they've solved their problem, which is completely understandable really, but a resolution report is so helpful to others if they happen to be fighting the same issue.
A lot of people seem to forget about doing so after they've solved their problem, which is completely understandable really, but a resolution report is so helpful to others if they happen to be fighting the same issue.
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