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Premium Remanufactured 4.5L / 6.0L Powerstroke Injectors 1 Year / 50,000 Mile Warranty
Our injectors are backed by a company with 60 Years of Experience in the Diesel industry. They are not just rebuilt - they are remanufactured to exacting tolerances and tested to meet precise standards in an ISO14001/TS16949 certified environment. 6.0L injectors are a demanding application - we provide you with unequaled quality at very competitive pricing.
NOTE: Scroll to bottom of page to order! How do 6.0L Injectors Work? The Powerstroke 6.0L injector is a HEUI Injector originally made by Siemens. HEUI stands for hydraulic electronic unit injection. A high pressure oil pump located at the back of the engine's valley area produces as much as 3,770 PSI. This pressure is used by the injector to generate the actual force which injects the fuel. Because the injector multiplies oil pressure by a ratio of 7:1, injection pressure can be over 26,000 pounds per square inch. Two 48-Volt 20-Amp solenoids control the position of a spool valve in the injector which routes high pressure oil into and out of the injector and ultimately controls when injection occurs. These injectors have a very fast response time and will actually perform several separate injection events for each power stroke for improved power and reduced engine noise. The injectors receive high pressure oil from a heavy duty rail located above the injectors, and receive fuel through cast passages in the cylinder heads. What are some common symptoms of injector failure? Typically when one injector fails, we find that the engine is hard to start and is low on power. If two injectors fail starting will be very hard or the engine will not start at all. If you do manage to start the engine, it will be very low on power. 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! Because engine oil at very high pressure is used to operate the injectors, keeping the oil clean is absolutely essential to maximum injector life. Extended oil change intervals are deadly to 6.0L fuel 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 next major issue that affects 6.0L injectors. Poor quality fuel with water or dirt in it is absolutely deadly to your injectors. Also, because the fuel actually provides a cushion for the internal valving of the injector, anything that causes low fuel pressure will kill the injectors. This includes not observing proper fuel filter maintenance. 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. Finally, running a 6.0L Powerstroke out of fuel is deadly to injectors! On early trucks, if you run out of fuel, you will usually be buying 8 injectors. If you think you are going to run out of fuel, stop, shut the truck off, and walk. It may save you $2,500. Later trucks have a PCM strategy which limits pressure to prevent injector damage during a low fuel condition, but it is still a situation to be avoided at all costs. 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 fuel injectors 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 cylinders are weak. -
Any time you suspect an injector issue, check fuel pressure. Correct fuel pressure is vital to proper engine operation. -
Combustion gas (air) entering the injector and fuel rail 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. There are two possible routes that air can enter through the injector. The first is through a worn/damaged needle and seat in the injector, the second is through a damaged copper washer at the bottom of the injector. Follow the following steps to find which cylinder is causing the problem: - Remove fuel pump and fuel injection control module relays
- Remove the fuel lines that run from the fuel filter housing to each cylinder head.
- Put a balloon over the end of each of the fuel lines coming from the head and use a rubber band or zip tie to seal the balloon tightly to the line
- Have someone crank the engine and watch the balloons closely for any sign of pulsing which indicates compression gas is being forced through the injector. This will allow you to determine which bank the problem is on.
- 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 injector(s) have a problem.
- Remove affected injectors, and look carefully at the copper gasket at the tip. The washer should display an even circular crush pattern. If in doubt, replace the washer and try again. Beware of missing washers, or possible installation of two washers.
- While injectors are removed, you can also use a hand vacuum pump to do a quick test for a damaged injector tip needle/seat. 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.
- Typically copper washer leaks will cause the balloons to fill up quickly, while internal injector leaks will only cause slight pulsing of the balloons.
Other Diagnostic Tips: -
Before beginning any diagnosis or parts replacement, always determine if your truck's PCM and IDM (Injector Drive Module) have been updated to the latest software. Recent changes correct hard cold start/cold smoke/poor cold running issues by energizing the injector coils during glow plug operation in order to heat the oil in the injectors. Software is VERY important to 6.0L operation. -
If oil is very dirty, change it and see if operation improves. -
The 6.0L has many issues with electrical harnesses rubbing through - even the updated harnesses. The injector harnesses can rub through near the valve covers and either prevent an injector from firing or cause it to stay on all the time. -
Any time a 6.0L develops a stalling problem or a miss, check the problem out right away to prevent possible further damage!
Replacement Instructions: -
6.0L injector replacement is not extremely difficult and does not usually require special tools, but is only recommended for those with at least a minimum of mechanical training. Please read the installation tips below to avoid common errors. -
EVERY time an injector is removed / replaced the copper tip washer and o-rings MUST be replaced. Do NOT install two copper washers (Be sure 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 go up the side of the injector and will burn the lower injector o-ring. This in turn will allow fuel into the cylinder which, in a worst-case scenerio, can cause hydro-locking and engine damage. This is NOT a warrantiable condition. -
Replacement time can vary from a few hours for a pickup to 8 for some van conversions. -
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 common causes of hard hot starting. (See related items below.) -
Torque on the injector retaining bolt is very critical! Earlier trucks require 24 ft-lbs, and later trucks, 26ft-lbs. Look it up for your truck! -
'Quick' Removal /Installation Guide (NOT a substitute for your manual): - Remove valve cover
- Remove 8 bolts that hold high pressure oil rail to rocker arm cover and pull straight up to remove. A special tool to disconnect the feed line from the rail allows you to remove the rail completely which is convenient.
- 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.
- Loosen the torx bolt that holds the injector in place. This will unseat the injector - do not use air tools, and do not pry on the injector coils which will damage them. Also, be sure the copper tip washer does not stay in the head.
- Reverse to install - be sure to lubricate all o-rings with engine oil before installation, and remember that injector hold down bolt torque is very critical. Seat high pressure oil 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 very carefully, the seals in the top opening of the injector will be damaged and high pressure oil leaks will result, ultimately causing a no start (typically when hot) and other driveability issues. 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!
- Upon starting the engine, it will run rough for a long time, until all the air gets out of the system.
Our injectors fit the following applications / part numbers: - Applications:
- Ford Powerstroke 2002.5 - 2009 6.0L
- 2003 - 2007 International VT365 6.0L
- Fits 2004 - 2006 International VT275 4.5L
- Part Numbers:
- 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 a remanufactured injector that, in many ways, is superior to the original. If you are interested in long-term durability, our updated 6.0L injectors are the answer! Core Policy: -
Cores must be returned within 60 days. Cores returned after 60 days are only eligible for a 50% refund. We really appreciate it if you can return them more quickly, but if you need longer, 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 the injectors are returned. Please be absolutely certain that you insure your injectors and retain the tracking number. 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 physically broken, or with broken solenoids or cut wires are not acceptable. -
If you have any questions about the condition of your cores, please ask. Warranty Policy: -
Please read the main warranty statement on our website. By purchasing you agree to the terms of the warranty. Please understand that we desire to treat our customers fairly and generate long-term relationships. We do NOT look for ways to get out of 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 or 50,000 miles. In addition to the normal warranty terms, injectors damaged by oil or fuel contamination, contact with engine coolant (blown head gaskets), high EGTs (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 mis-diagnosis 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 you misdiagnosed the problem. 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.
PLEASE NOTE: - All injectors come with NEW O-rings and tip gaskets included. - Please read 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
Code: INJ_FORD_60
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