Decided To Do The Full Monty On My 6.0 Liter PSD F-550 Top Engine
I ordered the parts to give my engine a big upgrade. The truck only has just over 90,000 miles on it but it is 20 years old. After I backflushed my oil cooler, I went to fire it up and was treated to a big cloud of heavy diesel exhaust smoke. I got a contribution error code on #2, front left, so I replaced that and made the mistake of thinking I was done but NOoooo, the smoke and rough running was still there. I hooked the scanner back up and now was getting a contribution error on #4. This was upsetting obviously. It takes a bit of time and effort to did down into the engine and replace an injector. For the #2 injector, I was in a hurry because we were planning to attend a family campout at Deception Pass State Park and now that wasn't going to happen. The 550 wasn't running so my plan B to load the TC onto the old F-250 couldn't be done. So, back to the engine. I pulled apart the left side again to examine things. I decided to pull all the injectors on the left side and replace all the injector O-rings with a set of Mahle Viton O-ring kit. Examining the engine components further, I noticed the oil rail cups were loose which would cause a major loss of oil and high pressure making the engine run rough. I ordered a set of Alliant Viton O-rings and an expensive specialty socket to replace all those O-rings. I also ordered new updated stand pipes and dummy plugs. That should address the high pressure oil side of things. I believe the injectors in the engine are Warren, a cheaper brand. I purchased a set of 8 Alliant injectors with all new internals and verified tolerances with complete testing before shipping, at least that's what they say. 2000.00 for the injectors which included new oil and fuel filters, valve cover gaskets and a couple other items. Cost goes down with a larger package. Injectors themselves I guess to be 1700.00 +/- by themselves. I'm also replacing glow plug #6, the turbo back pressure sensor since I'd had a code on that before. I'm also installing new cam and crank position sensors. My FICM is an Alliant 50 Volt version dated July 2022 so that should all be just dandy. The plan is to pull apart the right side today and have the engine all ready to install all the new stuff when it gets here by Tuesday. The problem has been identified as an over fueling issue. I took my bore scope to look down into each cylinder and In #4, I could see lots of carbon and diesel fuel on top of the piston. Other pistons looked wet but not soaked like #4. So anyway, That's the state of the truck address for now. I'll provide video of the project when finished for the 3 or 4 hard core engine loving folks that will want to watch it. More details to came as they happen.
#2#6#4, the bad one#8#2 injector pulled#2 injector pulled, #4, #6 Warren injectors. #4 is now indicating the contribution error. #8 is a Motorcraft installed last year. It had the bluest tip indicating heat I believe. Injector cups look to be in good condition so will clean and reuse.
