How to Properly Test and Replace Faulty Injectors on Ford 6.7L Powerstroke

How Injectors Work on the Ford 6.7L Powerstroke

The fuel injection system on the Ford 6.7L Powerstroke is an integral component to providing power, efficiency, and reliability. Most people don’t think about their injectors unless they encounter a problem. However, understanding how they work and how to properly test them can save owners time and money down the road.

The Piezo-Electric Injector Design

Ford utilizes a high pressure piezo-electric injector design on the 6.7L Powerstroke. Piezo injectors operate differently than traditional solenoid injectors. They utilize a piezo crystal that changes shape when voltage is applied, unlike a solenoid that uses an electromagnetic coil. This allows for greater precision and faster injector response times.

High Fuel Pressure Operation

The 6.7L Powerstroke fuel system operates at pressures over 30,000 PSI. This higher pressure allows for better fuel atomization and more exact fuel metering control. In order to achieve these pressures, the CP4 high pressure fuel pump pressurizes the fuel before sending it to the piezo injectors.

Testing Your 6.7L Injectors

If you suspect issues with one or more injectors, there are a few tests that can be performed. This helps properly diagnose problems before replacing expensive injector components.

Check for Leaks

Visually inspect the injector bodies, connectors, and fuel lines for any signs of leaks. Clean the areas and further inspect. Even small leaks can cause performance issues or fuel dilution in the engine oil.

Listen for Abnormalities

With the engine running, listen around each injector. Properly operating injectors will have a steady clicking or ticking noise. Irregular sounds can indicate worn components or failure.

Balance Rates Test

A more advanced test is to utilize a diagnostic scan tool and measure balance rates. This shows the fueling contribution of each cylinder. Significantly lower numbers on a particular cylinder can indicate a bad injector.

Buzz Test

Detach the fuel rail from the injectors and use a special tester that buzzes them open for a brief period. This checks atomization quality and spray pattern. Variances between injectors points to ones that may need replacement.

Replacing 6.7L Powerstroke Injectors

If one or more faulty injectors is confirmed, replacement will be necessary. Always replace in sets to maintain performance. Fortunately, many aftermarket options are available to upgrade over the factory units.

Removal and Installation

Proper injector removal and installation procedures must be followed to avoid damage and ensure leak free operation. The job requires special tools and patience to complete successfully.

Tuning Required

After new injectors are installed, a tune upgrade is highly recommended. This allows the truck’s computer to properly control the new injectors. Without a tune, poor running conditions can occur.

Understanding how the high pressure piezo-electric injectors operate on Ford’s latest diesel platform helps owners properly test and diagnose issues related to fuel delivery. Following the proper maintenance procedures will keep your 6.7L Powerstroke diesel running smoothly for years to come.

FAQs

How often should injectors be tested?

Ford recommends periodically testing injectors, with more frequent testing as the miles accumulate. Every 20,000-30,000 miles is a good guideline for a visual inspection and listening for abnormalities. More formal tests may only be needed if issues are suspected.

What are the most common 6.7L injector failures?

The most common failures on the 6.7L Powerstroke injectors are cracked bodies causing leaks, connector issues leading to electrical faults, clogged nozzles affecting spray patterns, and failures of the piezo crystals causing unstable operation.

Is any programming required with new injectors?

Yes, new injectors should always be followed up with an ECU tuning. The truck's computer stores data about the old injectors that it relies on for fuel calculations. A tune reprograms it for the new injector flow characteristics.

Can I change just one failed injector?

It is not recommended to replace just one failed injector if others have similar mileage. It is best practice to replace all injectors in complete sets to maintain performance and reliability across all cylinders.