The short version of this story is that I drove 9k worry free miles. Then it started puking and the dealer removed the cab to do both head gaskets and the EGR cooler. One of the heads was not seated on the alignment dowel. Within 200 miles I lost an injector. in another 1,000 miles lost another injector. 300 more miles and I lost 2 more injectors. I only have 11k miles on this truck and never had injector problems until they did the head gaskets. I am not running a tuner of any kind and there is no CEL or any other warning. When it starts to misfire it will be completely dead in less than a mile.

The tech said he has no idea why my truck is doing this and what really seems strange to him is that in each case this has happened it has "burnt the copper gasket under the injector". I havent done the fuel filter yet but the tech is telling me that wouldnt burn the gasket. I have read the tips on here and I change my oil every 3,000 miles and also run PS additive in the fuel with every tank. Im hoping that the burnt gaskets will trigger an answer to this problem.

Thanks in advance for your feedback.

 

Improper torquing of the injector during installation causes that failure. Have you lost the same injector more than once. or are the injectors just failing like falling dominoes?

 

lost #6 the first time, #7 the next time, and #1 and #3 this last time. so far all different.

By improper torquing do you mean too tight or too loose? should he have replaced those gaskets when the engine was in 50 pieces having the HG's done? Or is it OK to re-use them?

 

When doing headgaskets, injector removal is required so you don't damage the nozzles. You are supposed to replace all o-rings and the copper gasket whenever you remove or loosen the injector, or failure will happen shortly. HMMMM...............

 

Ding, Ding, Ding... We have a winner! Listen to this guy caprang (check his sig) Now go to your dearler with a head full of knowledge graciously requesting a complete correction of the problem(s).

 

That makes perfect sense to me!! I am going to ask the tech tomorrow if he did this but I am fairly sure that he didnt. If he did, the part(s) didnt show up on my repair order anyway.
I will post an update tomorrow but Im willing to bet this is it. Thanks!!!

 

Talked to the tech today and he claims that he DID replace the O-rings and gaskets since that is "standard procedure". Wouldnt those parts have shown up on my repair order? As we were talking he did mention that as a result of my truck he has started thoroughly scrubbing/cleaning every part as he puts them back together. Hmmm. I remember going to the dealer to see the status of the HG repair and all the injectors were laying in a box with other bolts and parts so maybe they had dirt on them when he reinstalled them?
I asked the tech for any options/suggestions because I will be relying on this truck for towing and right now I dont trust it. His only suggestion was to drive it as much as possible to see if I can get it to fail again. The service manager suggested I lemon law the truck. Is that really the answer?