What caused this?
 

Short story is the truck was running well but I started to hear what sounded like an exhaust manifold leak or a blown head gasket. As I started to accelerate to merge with another freeway it stumbled and sounded like the engine was ready to spit out some parts. I shut it down and towed it home. The computer said number 4 cyl had a contribution balance problem. So I pulled the number four injector and it looks like this. It has only been the engine for a few weeks but was used when installed. It did not have any discoloration when I installed it with new seals and torqued it to 28 ft lbs.

http://i1307.photobucket.com/albums/...9/DSCF1983.jpg

http://i1307.photobucket.com/albums/...9/DSCF1985.jpg

Poor sealing copper washer, allows combustion gases to enter the injector cup

Did you make sure to clean out that injector cup and injector clamp bolt hole? Oil or fluid in the clamp (holddown) bolt hole will prevent proper seating pressure

Was the hold Down Bolt Hole CLEAN when Installed????

Also replace Injector Holddown this time

Was the truck pouring smoke out the Back???

Good Call Brett

Did the injector get stuck on????

thanks
 

I did clean out the hole and cup on install. The copper washer shows no sign of any leakage. It is clean and shiny all around. Is there any other place for compression to enter the area below the fuel o-ring? A cracked head maybe?

oops
 

Sorry there was no noticeable smoke. How to tell if it was on?

The only other thing i could think would be a crack in the injector cup? can you take a photo of the end of the injector.

Sure can

http://i1307.photobucket.com/albums/...9/DSCF2006.jpg

http://i1307.photobucket.com/albums/...9/DSCF2002.jpg

from what it looks like those washers look pretty good, kinda hard being black and white photos but they dont look discolored on the sealing surface.

And thanks Benny

The washers look good to me. Sorry for the black and white. My camera does not like close ups and that helped. I did not pull the washer and look below but the top shows no sign of any leakage. Can it come through the injector itself or is a cracked cup the only place for compression to get inside the cup? Going back to the noise it made like a blown gasket could that be related to the compression in the cup?

Just replaced my Injectors, well my mechanic did Jesse' instructions said 31 Lbs. Tq.

Denny

They started at 24ft/lbs Ford spec

Last time mine was out I went 26ft/lbs on the Holdown

If inject cup was cracked you would have Diesel Fuel in the Coolant But the Injector wouldnrt be Burned

Are you shure there isnt another Copper washer in the Inject cup
Was there 2 copper washers in there

Maybe that inject didnt get torqed all the way IDK

But Replace the Holdown this time maybe its Bad IDK

Did the previous inject look like this???????????

Thanks to all
 

The old injector did not look like this one at all. Minor discoloration only. The stuff on this injector was thick like it had been getting contaminated from the install. I will check the cup to make sure there is not a second seal within. All the injectors replaced had seals attached but you never know if you don't look. I will clean everything thoroughly including the bolt hole and reassemble with new seals and a new hold down see and what happens. Is there a way to run a compression check at this stage. Someone must make an adapter that goes in where the injector does.