1. 6.0L Powerstroke Injectors
Super 6.0L Injector Sale!
Only a few sets left - Our best injector (Option 2) is currently on sale for $182.95 each -
normally $223.95!
Premium Remanufactured 4.5L / 6.0L Powerstroke Injectors
1 Year / Unlimited Mileage Warranty
AccurateDiesel.com now offers two 6.0L injector options - read about them in detail
below along with diagnostic and installation information. Our unlimited mileage
warranty runs circles around the 12,000 miles offered by our largest competitors. 6.0L
injectors are a demanding application - we provide you with the highest quality at very
competitive pricing.
NOTE: Scroll to bottom of page to order!
Option 1 $194.95 plus Core
Premium Remanufactured Injector
-Remanufactured by a Tier 1 Automotive Supplier (Tier 1 means that
the company supplies directly to a major automobile manufacturer.)
- Not just repaired - Remanufactured in an ISO4001 and ISO TS
16949 certified environment
- Every single injector is built to meet or exceed manufacturer's
2. specifications
- All injector clearances are measured using precision air gauges to
ensure conformance to standards. Each injector is individually serial
numbered by laser and measurement data retained by serial number.
- Each injector is individually tested and data recorded to ensure a
quality product.
- Thousands of these injectors have been installed worldwide in both
end-user and fleet / commercial applications.
Option 2: Normally $223.97 plus Core - On sale for $182.95 each plus core
OEM Remanufactured Injector
- For those customers who are seeking an injector a 'cut above the rest'
we now carry injectors remanufactured by the company that built them
in the first place.
- These injectors feature a BRAND NEW spool valve in every single
injector. Years of experience with the G2 HEUI injector led to the
conclusion that this is the best practice to archive the ultimate in long-
term trouble free operation.
- NEW Spring and Plunger in every injector.
- NEW Solenoids, wiring, and connector in every injector
- Years of improvements and updated specifications applied to every
injector (includes vented end caps to prevent stiction)
- For the customer willing to spend a little more to have the assurance
that they are getting the best available, this is the ultimate 6.0L Injector
How do 6.0L Injectors Work?
The Powerstroke 6.0L injector is a HEUI Injector manufactured as the result of a joint
venture between Siemens AG and Navistar International Corporation. 'HEUI' stands for
hydraulic electronic unit injection. A high pressure oil pump located at the back of the
engine's valley produces as much as 3,770 PSI. This high pressure oil acts on an
intensifier piston inside the injector where pressure multiplication occurs at a ratio of 7:1
generating actual injection pressures over 26,000 PSI. Twin 48-Volt 20-Amp open and
close solenoids control the position of the injector's spool valve which ultimately
determines the duration and timing of fuel injection.. High pressure oil is delivered to the
injectors via an oil rail located above the injectors while fuel is received through a passage
cast into each cylinder head.
What are some common symptoms of injector failure?
Hard Starting (especially w/ cold engine)
Excessive Smoke
Rough Running
Low Power
3. Stalling
Misfire
Bucking / Jerking
Our experience is that when one injector fails, the rest are not far behind. From a time
and labor standpoint it usually makes sense to replace the injectors as a set!
What causes 6.0L Injector Failure?
Besides design issues, the #1 cause of 6.0L injector failure is poor maintenance! The
closest tolerances in the engine are found in the fuel injectors. Therefore, keeping the oil
clean is paramount to realizing maximum injector life. Extended oil change intervals are
deadly to 6.0L injectors - unless you are running a good bypass filtration system. We
highly recommend the FS-2500 bypass oil filtration system if you are intent on extending
the life of your injectors.
Besides keeping the oil clean, fuel is the second major issue that affects 6.0L injectors.
Poor quality fuel containing dirt and water is a recipe for 6.0L injector disaster.
Additionally, because fuel in the injector is used to provide a cushioning action for the
internal valving of the injector, low fuel pressure will severely harm the injectors. Clogged
fuel filters caused by neglected maintenance intervals are a common reason for injector
damage. We recommend that fuel filters be serviced at 15,000 mile intervals. Low
pressure caused by a failing fuel pump can cause repeat injector failure. ALWAYS check
fuel pressure after installing new injectors - it should be between 45 and 55 PSI and
should not drop below this spec under load. Running a 6.0L Powerstroke out of fuel
should be avoided at extreme cost. If you think you are going to run out of fuel, shut the
truck off, and walk - it may save you $2,500. We have seen early trucks require a
complete set of eight new injectors after enduring fuel starvation. Later build trucks
incorporate a PCM strategy which limits pressure to prevent injector damage during a low
fuel condition, but we strongly recommend that testing the effectiveness of this strategy be
avoided.
Tips for diagnosing faulty 6.0L Fuel injectors:
Please note that we cannot begin to cover all the diagnostic strategies and possible failures
of the 6.0L injection system here. These are just some useful tips we have found. The
starting point is always to check for cylinder contribution codes using a Ford IDS / WDS
or similar scan tool. Follow this step with a cylinder balance test which creates a visual
display of crankshaft RPM variation allowing you to see which cylinder(s) are weak.
1. The starting point for 6.0L injector diagnosis is often the scan tool. A Ford IDS or
quality aftermarket scan tool may be used. The first step is to check for codes. Two
types of codes may be found - These are cylinder contribution codes, and electrical
fault codes. NOTE: Cylinders numbered 2, 4, 6 and 8 are on the driver's side of the
engine. Cylinders numbered 1, 3, 5, and 7 are on the passenger's side. Higher
numbers are toward the rear.
4. 2. If electrical fault codes are present, do NOT assume that the injector is at fault.
Concerns with the fuel injection wiring harness are very common and may cause
extremely troubling intermittent conditions. Close visual inspection of the harness
running between the FICM (fuel injection control module) and the injectors,
especially where it rubs against the valve covers, intake manifold, and intake
manifold mounting bolts is very important. Chafing of the insulation is very
common in these areas. Often replacement of an injector or FICM will appear to
correct a problem temporarily, but the problem will reappear as the wire resumes
its original position.
3. Cylinder fault codes (without electrical codes) also do not automatically indicate
that the injector is at fault. Keep in mind that there are other reasons a given
cylinder may not contribute it's fair share to the engine's operation. Many better
scan tools will allow a relative compression test to be performed from the comfort
of the driver's seat by comparing the draw of the starter (and the corresponding
drop in battery voltage) during cranking as each cylinder goes through the
compression stroke. We have seen many cylinder contribution codes caused by
simple and easily repaired upper valve train problems such as broken rocker arm
bridges or bent push rods.
4. In order for 6.0L injectors to operate correctly, they must have sufficient quantity
and pressure of good clean engine oil and fuel. Before condemning injectors,
always check engine oil level and change it if it has been neglected. Taking a fuel
sample and inspecting it for any contamination, as well as measuring fuel pressure
(there is a plug on the secondary fuel filter housing for this purpose) are highly
recommended.
5. Fuel injection control module issues are another common cause of 6.0L fuel
injection concerns. If FICM codes, multiple fuel injector circuit low codes, or code
U0105 are present then pursue FICM diagnosis and possible replacement before
faulting the injectors.
6. Combustion gas (air) entering 6.0L injectors and fuel rails is a common problem
and will cause a random misfire not only on the cylinder the problem originated
on, but on other cylinders as well once air enters into the fuel rail. If multiple
misfires are present, predominately on one bank, suspect this fault. By far the most
common route for combustion gas to enter the system is via a leak past the copper
gasket at the tip of the injector. After leaking past the tip gasket, gasses under high
pressure will blow past the lower o-ring on the outside of the injector and allow air
into the fuel system. As the failure progresses over time, fuel under pressure will
eventually find its way into the cylinder following the reverse path as the
combustion gasses. This will at first result in massive quantities of white smoke,
and shortly thereafter in a hydro-locked engine.
Follow the following steps to find which cylinder is causing the problem:
o Remove the fuel pump and fuel injection control module relays
o Remove the fuel lines that run from the fuel filter housing to each cylinder
head.
o Put a balloon over the end of each of the fuel lines coming from the head
5. and use a rubber band or zip tie to seal the balloon tightly to the line.
o Have a helper crank the engine and watch the balloons closely for any sign
of pulsing which indicates compression leakage. This will allow you to
determine which bank the problem is on.
o Remove all but one glow plug from the bank with the problem. (Removing
the glow plugs relieves compression in the cylinder.) Crank the engine and
move the glow plug from cylinder to cylinder to find which one is affected.
o Remove affected injectors, and carefully observe the copper gasket at the
tip. The washer should display an even circular crush pattern and there
should be no carbon above the washer. If in doubt, replace the washer and
try again. Beware of missing washers, or possible mistaken installation of
two washers.
o While injectors are removed, you can also use a hand vacuum pump to do a
quick test for a damaged injector tip needle/seat (a possible second path for
air into the injector and fuel rail). Locate a piece of rubber hose that fits
tightly over the end of the injector tip and push it on. Connect the opposite
end of the hose to the pump and apply vacuum. If the injector will not hold
a vacuum, it must be replaced.
o Alternate methods of detecting combustion gas leaks:
For very small leaks attach a piece of rubber hose to the fuel line
from each head and insert the hose into a glass of water and observe
for bubbles.
Some techs remove the top cover of the secondary fuel filter and
observe for bubbles rising in the filter housing while cranking (with
FICM and fuel pump relays removed!)
Additional Tips:
Before beginning any diagnosis or parts replacement, always determine if your
truck's PCM and FICM have been updated to the latest software. Several program
updates are available to correct hard cold start, no cold start, white smoke, and
poor cold operation issues by energizing the injector coils using an inductive
heating strategy to prevent the injector spool valves from sticking until the engine
has reached normal operating temperature. Correct up to date software is critical to
satisfactory 6.0L operation.
Any time a 6.0L develops a stalling problem or a miss, check the problem out right
away to prevent further damage!
The word 'Stiction' combination of the words 'sticky' and 'friction'. Stiction affects
the operation of the injector's spool valve and will result in rough engine operation
especially when the engine is first started. Maintaining clean engine oil of the
proper type and viscosity at all times will prevent contaminants from developing
inside the injector and causing stiction.
Replacement Instructions:
6.0L injector replacement is not extremely difficult and does not usually require
6. special tools, but is only recommended for those with at least a minimum of
mechanical training. It does require strict attention to the details mentioned below -
Please read the following to avoid common errors.
EVERY time an injector is removed / replaced the copper tip washer and o-rings
MUST be replaced. Be sure not to install two copper washers (Ensure the old one
did not stay in the head.) CAUTION: The seal between the tip of the injector
(where the copper tip washer contacts the head) is very critical. Make sure this
area is clean, that only one washer is installed, and that the injector retaining bolt
is properly torqued. If a leak occurs in this area, combustion gases will pass up the
side of the injector and burn out the lower injector o-ring. This, in turn, will allow
fuel into the cylinder which, in a worst-case scenario, can cause hydro-locking
and engine damage. This is NOT a warrantable condition.
Book time for a single injector replacement on a pickup is 1.6 hours with
additional injectors on that side paying 0.2 hours each. Vans are much more
difficult and replacing an entire set can consume 8 hours.
Owners of 2004.5 and newer trucks should consider replacing the standpipe and
dummy plug seals while the valve covers are off - leaks at these locations are a
common cause of hard hot starting. (See related items below.)
Torque on the injector retaining bolt is very critical! Early build trucks with a T40
retaining bolt require 24ft-lbs. Later trucks with T45 retaining bolt require 26 ft-
lbs.
'Quick' Removal /Installation Guide (NOT a substitute for your manual):
o Remove valve cover
o Early build trucks (before 2004.25) will have a tubular style oil rail that
requires a special tool to disconnect the supply line from the oil rail (such
as OTC 6594). In most cases it is not actually necessary to disconnect the
rail. You can gently move it around to clear the injector as needed.
o Later build trucks require removal of the high pressure oil standpipe that
delivers oil to the 'wavy' design oil rail. The standpipes require an allen
wrench for removal.
o Remove the 8 bolts that retain the high pressure oil rail and pull straight up
to remove.
o Inspect the oil inlet area of the injectors for metal shavings which indicate
high pressure oil pump failure in process. If shavings are found, the high
pressure oil pump must be replaced and the system flushed or failure of the
new injectors will occur in very short time. Also note that if the tops of any
injectors are broken off the cause is insufficient fuel pressure or air in the
fuel and that this issue must be corrected to prevent short-term
reoccurrence.
o After disconnecting the electrical connector, use a 19mm 12 point chrome
socket to push the remaining portion of the connector body out of the
rocker housing.
o Loosen the torx bolt that holds the injector in place. Be sure to use a
medium length torx bit to avoid making contact with the solenoid on the
injector and breaking it off. Unscrewing the injector hold down bolt will
unseat the injector - do not use air tools, and do not pry on the injector coils
7. which will damage them. Also, be sure the copper tip gasket does not stay
in the head.
o Before installing the injector be sure that the injector cup in the cylinder
head is perfectly clean, particularly the tip gasket and o-ring contact areas.
Lubricate the o-rings with engine oil before installation.
o Before tightening the injector hold down bolt, clean any oil out of the bolt
hole. Oil remaining in the bolt hole will cause the bolt to tighten before the
injector is seated resulting in catastrophic failure. Remember that injector
hold down bolt torque is very critical.
o Lubricate the inlet tubes on the high pressure oil rail with engine oil and
seat the rail by hand before tightening bolts. CAUTION: Not seating the oil
rail properly when installing the rail back on the injectors is the #1
installation error. If the rail is not installed with finesse, the injector inlet
seal will be damaged and a high pressure oil leak will result, ultimately
causing a hard hot start condition. Seating the rail properly is not difficult,
just be careful to work it into the injectors slowly and keep it square so the
seals are not damaged. Do not use force!
o Changing the engine oil, oil filter, and primary and secondary fuel filters is
recommended.
o Be aware that the engine will be somewhat difficult to start since air has
been introduced into the oil and fuel systems. Upon starting, the engine
will run rough for some time until all of the air has purged.
Our injectors fit all 6.0L Ford Diesel engines including the following applications /
part numbers:
Applications:
o Ford Powerstroke 2002.5 - 2009 6.0L
o 2003 - 2007 International VT365 6.0L
o 2004 - 2006 International VT275 4.5L
Part Numbers:
o 3C3Z-9E527-AE, 4C3Z-9E527-AA, 1843089C91, 1845879C91,
1843481C94, 1843481C95, 1844751C2, 1846692C92
Each and every 6.0L Powerstroke injector we sell is updated to meet the latest calibration
standards (no need to worry about which injector your truck was originally equipped
with). Years of testing, field experience, and engineering analysis have resulted in the
production of remanufactured injectors that are second to none. If you are interested in
long-term durability, our updated 6.0L injectors are a wise choice.
Core Policy:
Cores must be returned within 60 days. Cores returned after 60 days still eligible
for a reduced refund based on how much time has elapsed. If more time is needed,
please contact us - we may be able to make special arrangements.
Core charge is $75 per injector. We refund this amount as quickly as possible after
8. the injectors are returned (typically within 24 hours on business days). Please be
absolutely certain that you insure your injectors, retain the tracking number, and
tape the box well. We are not responsible for injectors we do not receive.
Injectors cannot be disassembled or have been disassembled. They must be in a
condition representative of normal use. NO junkyard cores that have been out in
the rain. Injectors that are externally broken may have reduced core value - feel
free contact us if there are questions..
Warranty Policy:
Our 6.0L injector warranty policy is among the strongest and most generous in the
industry. Please read the main warranty statement on our website as well. Please
understand that we desire to treat our customers fairly and generate long-term
relationships. We do NOT look for ways to escape honoring legitimate claims in
the rare case that they occur. When in doubt, we will favor the customer.
6.0L injectors are warranted for one year with no mileage limitation. In addition to
the normal warranty terms, injectors damaged by oil or fuel contamination, contact
with engine coolant (blown head gaskets), high EGT's (performance/racing), or
mechanical engine failure may not be eligible for full warranty coverage. We are
NOT liable for any incidental or consequential damages of any kind. Also, we
cannot accept the return of injectors because of customer misdiagnosis of a
problem. 6.0L engines can be very challenging to diagnose, and the best of us are
sometimes wrong. If you install our injectors and have the exact same problem you
did before, chances are 99.99% that a misdiagnosis occurred. Please do not ask if
you can return them in that case. Any returned injectors that pass our testing are
not accepted for warranty except under very special circumstances.
Tip gasket failure is not the fault of the injector, but rather the engine (injector
sleeve) or the installer, and is therefore not a warranty condition .Cleaning the
injector, installing new external seals, and properly re-installing the injector will
correct the problem.
Operating the engine with insufficient fuel pressure or with air / combustion gas in
the fuel will result in the top of the injector being hammered off. This is also not a
warranty condition. Probable causes are: Tip gasket failure, bad fuel pump,
plugged fuel filters, defective fuel pressure regulator, etc.
PLEASE NOTE:
- All injectors come with NEW O-rings and tip gaskets included. There is no need to
purchase a seal kit separately.
- Please read the core policy above. If you would like to avoid the core fee, just select
below that we should hold shipment until you send your cores.
- See related items below for additional items to consider when replacing injectors.
$194.95
9. Code: INJ_FORD_60
Injector Option:
Core Option :
Quantity: 1
Shipping: Estimate Shipping
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Related Items:
Glow Plug Set - Ford 6.0L Standpipe / Dummy 6.0L Ford Powerstroke
PowerStroke 6.0L Plug Seal Kit $73.95 Late HPOP w/ IPR
set of 8 $74.95 Code: AP0028(2x) (fits 2004.5 - 2010)
Code: GP_FORD_60 $639.95
Code: HPOP_60Late
6.0L Ford Powerstroke
Early HPOP
(fits 2003 - 2004.5)
$589.95
Code: HPOP_60Early
