6.7 Powerstroke Diesel Injectors failing at low mileage?

[Audiman]

Think of it like this, if you replaced the cam cover gasket the injectors would be removed and then reinstalled you wouldn’t replace them then would you. You’re paying the bill not Ford so tell them to follow instruction it’s your dollars. I have dealt with this issue before on v6 and v8 diesels and it is the injector at fault however the engine ECU does not correctly identify the one at fault.

What is your battery voltage with ignition on the ln what does the voltage drop to while cranking the engine?

 

[mbacfp]

Think of it like this, if you replaced the cam cover gasket the injectors would be removed and then reinstalled you wouldn’t replace them then would you. You’re paying the bill not Ford so tell them to follow instruction it’s your dollars. I have dealt with this issue before on v6 and v8 diesels and it is the injector at fault however the engine ECU does not correctly identify the one at fault.

What is your battery voltage with ignition on the ln what does the voltage drop to while cranking the engine?

Interesting, not a tech, so pardon my ignorance. Are you suggesting the ECU/PCM isn't correctly identifying the bad injector?

Appreciate the help...just want to make sure I am understanding...

 

[mbacfp]

Interesting, not a tech, so pardon my ignorance. Are you suggesting the ECU/PCM isn't correctly identifying the bad injector?

Appreciate the help...just want to make sure I am understanding...

Don't know voltage info...but maybe I can find out when I go there next Thursday.

 

[mbacfp]

Update:

Tech heard back from Ford Engineering and wants them to run a couple of tests that are not in the service manual. I asked which ones, but doesn't know exact names/procedures. So, will be a couple of hours I've been told.

 

[oil pan 4]

The 33966 is a 2 micron filter. The 33966NP is smaller than 2 micron.

This is the way.
There's probably one that fits fords..

 

[bdcardinal]

They can't return a PCM because once the tamper proof tape is cut, Ford will not take it back from the dealer. Also there are one time use parts when replacing injectors. The seals on the injector tips and the hard lines to the rails are not supposed to be reused per the mothership.

Pictures of said tape:

 

[mbacfp]

They can't return a PCM because once the tamper proof tape is cut, Ford will not take it back from the dealer. Also there are one time use parts when replacing injectors. The seals on the injector tips and the hard lines to the rails are not supposed to be reused per the mothership.

Pictures of said tape:

View attachment 297605View attachment 297606

Ok, good. Dealer is being honest. I actually appreciate them and believe they have been acting in good faith this whole time. Have my issues with Ford as a company, but not with this Dealer so far.

 

[Audiman]

Yeah so you just replace the seals bolt and the pipes on the injectors. Must be what 20 dollars worth of parts.

You’ve tried both a ECU and a wiring harness, for me looking at what’s been changed and how it’s been looked at as a diesel tec from England this truck has a Bosch ECU Bosch injectors and a Bosch hp fuel pump, they are not made by Ford, you need to work through the injectors and find the one that’s got a issue, it may have low resistance at cold start triggering the fault code. Every time I’ve seen this happen the ECU never correctly identifies the right injector. If you’re lucky it will be 6 or 7 but it may be 1,2,3 or 4. Sometimes it’s easier to fit a full set but that’s expensive so you need to work though using the good ones that have been removed and see if you can find one that’s causing your faults.

 

[Audiman]

If you can get your Ford dealer to fit the 2 injectors they have removed to 6 and 7 if that doesn’t fix it do 1 and to the if needed 3 and 4. It should only cost you some labour and the seals bolts and pipes so should be cheeped than the parts cannon

 

[mbacfp]

Yeah so you just replace the seals bolt and the pipes on the injectors. Must be what 20 dollars worth of parts.

You’ve tried both a ECU and a wiring harness, for me looking at what’s been changed and how it’s been looked at as a diesel tec from England this truck has a Bosch ECU Bosch injectors and a Bosch hp fuel pump, they are not made by Ford, you need to work through the injectors and find the one that’s got a issue, it may have low resistance at cold start triggering the fault code. Every time I’ve seen this happen the ECU never correctly identifies the right injector. If you’re lucky it will be 6 or 7 but it may be 1,2,3 or 4. Sometimes it’s easier to fit a full set but that’s expensive so you need to work though using the good ones that have been removed and see if you can find one that’s causing your faults.

I appreciate that. I mentioned something similar early on and they reminded me that each injector has its own pigtail direct to the PCM and their own grounds.

Due to the nature of the codes only at startup...I thought maybe batteries? I'll try to swap batteries soon to rule out as they are also due to be changed.

At this point anything is possible.

 

[Audiman]

Yes that’s correct but what happens inside the ECU? Prior experience with Bosch ECU’s tells me that they struggle to correctly assign injector faults. It’s experience with a fault like this that helps you fix a fault like this.

Your last words are the only 100% correct words on this whole thread. Anything is possible and you only know what is causing the fault once you have fixed the fault. All prior ideas have the potential to be correct or not. Do not dismiss any idea until you have fixed the fault.

 

[mbacfp]

Yes that’s correct but what happens inside the ECU? Prior experience with Bosch ECU’s tells me that they struggle to correctly assign injector faults. It’s experience with a fault like this that helps you fix a fault like this.

Your last words are the only 100% correct words on this whole thread. Anything is possible and you only know what is causing the fault once you have fixed the fault. All prior ideas have the potential to be correct or not. Do not dismiss any idea until you have fixed the fault.

I will forward this info to the tech and see what they think. Will try and get info on what tests they are planning on running next Thursday. Purchased new batteries tonight and installing tomorrow. Least will rule that out.

Again, codes only come on shortly after start up...either cold or warm...doesn't matter.

Appreciate the info and experience. Never thought I would be this deep in solving this...but in it now. Will see it through.

 

[mbacfp]

I find it interesting that P1555 (#5) and P1558 (#8), the two codes I get (#8 with #5 intermetedily) but P1555 always is on the same side.

Coincidence or means something? Night all.

 

[mattd]

This is why I wanted to know all injector resistances, and resistances to ground.

 

[mbacfp]

This is why I wanted to know all injector resistances, and resistances to ground.

I'm hoping that checking them all was done before PCM recommendation? Certainly before Ford Engineering said wiring harness?

I'll let you all know if batteries make a difference tomorrow. Going to drive and get diesel...so multiple stops. Fingers crossed...

Night all. Thanks for putting up with me...

 

[mbacfp]

Replaced both batteries. Didn't fix, however now I'm getting P1555 and P1556? On same side of block...maybe one of the injectors on that side is messed up causing this? I have replaced #8 and #5...maybe #6 or #7 is the culprit? Weird. Make it a great day.

 

[mattd]

They need to check all the injectors especially on that bank, cold and warm engine resistance and resistance to ground/injector body

 

[mattd]

Did they ever check all the chassis to battery grounds? Especially ones coming from the ECM.

 

[mbacfp]

So far I've only paid for the new PCM, diagnostic fee, and install which was around $2,200. When they said wiring harness, the service advisor asked if I could pay the difference which was $500 and they were going to eat the PCM, etc. Now, not being the wiring harness...I can only assume that will be eaten as well. Honestly, I'm ok paying for the wiring harness part at dealer cost as that isn't something you can just remove without substantial labor.

I have printed out sections of this thread and left on front seat for tech to look at per the service advisor. He has looked at everything per service advisor. Will do the same with @mattd and @Audiman's info.

 

[mbacfp]

Will leave names and source out. Not sure what tests they have planned, but will include these extra thoughts for good measure. Appreciate all the help.