This fellow has been complaining of a strange miss during warm up. We ran injector deviation tests and were still not able to detect which injector was failing. During the road test with engine at operating temperature no miss was detected but a slight random fuel knock was. We suggested to the owner that it would be in his best interest to let us remove the injectors and send them out to be checked, he didn't want to take the truck out of service for two days.
We had also been having increasing issues with the after treatment system, the DPF kept getting plugged. The driver also started to complain about the engine oil usage increase.
This miss went from slight to well.... noticeable. Injector #5 had five of the six orifices plugged in the injector nozzle. As you can see it did eventually cut a hole directly through the piston, piston rings and wrist pin clip. The marks you see on the top of the piston are from the related parts that were cut apart. The head is reusable, but warranty is paying for a reman. Surprisingly enough the injector tip remained untouched. We will be replacing rod bearings, piston, liner and injector on cylinder #5. We are still in the process of trying to get a new DPF for the owner through warranty.