All Injectors Stuck Open/ Engine failure

[walleyewarrior]

This 08 comes in for a no start issue, i have no high pressure fuel most it builds is 60 psi. So do a visual, first thing noted is crankcase is way over filled, Ok no problem, so we pull the glow plugs out crank it over and find 1 and 2 are misting bad, we put 2 injectors in it and retry. still not building pressure, we take samples of fuel from water seperator, look in bottom of seconadry and unhook a fuel injector line and take a sample. it all looks good, Anyways it didnt sound right to me while tech was cranking it so i got him to do a compression test, 2 show max 100 psi, so im thinking ok bent rod from prob injecotor. so he tears down engine and we find that all the injectors are just dripping away. every cylinder is full of full, turbo was leaking oil out outlet, and 4 pistons are melted away. This truck is going to need a drop in for sure but my question is what would cause these injectors to do that?!?!? no injector recall on truck. and would the low fuel pressure be cause the other injectors were stuck open? or is the pump done? the mist test dint show anything on other cylinders only revealed once heads came off. it wasnt hydraliced wen it came in cause we were able to crank it over no problem, anyone else run into this????

[rlchv70]

Usually see that when HP pump goes out, sending debris to the injectors.

[DwayneGorniak]

This 08 comes in for a no start issue, i have no high pressure fuel most it builds is 60 psi. So do a visual, first thing noted is crankcase is way over filled, Ok no problem, so we pull the glow plugs out crank it over and find 1 and 2 are misting bad, we put 2 injectors in it and retry. still not building pressure, we take samples of fuel from water seperator, look in bottom of seconadry and unhook a fuel injector line and take a sample. it all looks good, Anyways it didnt sound right to me while tech was cranking it so i got him to do a compression test, 2 show max 100 psi, so im thinking ok bent rod from prob injecotor. so he tears down engine and we find that all the injectors are just dripping away. every cylinder is full of full, turbo was leaking oil out outlet, and 4 pistons are melted away. This truck is going to need a drop in for sure but my question is what would cause these injectors to do that?!?!? no injector recall on truck. and would the low fuel pressure be cause the other injectors were stuck open? or is the pump done? the mist test dint show anything on other cylinders only revealed once heads came off. it wasnt hydraliced wen it came in cause we were able to crank it over no problem, anyone else run into this????

 

 

Yup! It seems that whenever we have an injection failure on these babies, The fuckers are blowed right the fuck up. Always a complete drop in in this case. They don't pay worth a fuck either. good luck.

[walleyewarrior]

O it blowed up REAL good! MY concern now is if pump has failed how do I cover my ass to make sure this thing isnt going to come back on us that they found rust in pump even thow all my sample look good. Should I cover my ass and get a fuel sample analyzed?

[DwayneGorniak]

Let your Service Manager make the executive decision that he or she should and quit taking that kind of responsibility on your own shoulders. It is their job to make these decisions and it our job to report all finding and let them deal with it. A sample would be a very good idea though.

 

 

Hope that helps.

[Jeff Adema]

So the root cause of this kind of engine failure is.....? Contaminated fuel, faulty pump, faulty injectors, ......?

[Adam_Dodson]

So the root cause of this kind of engine failure is.....? Contaminated fuel, faulty pump, faulty injectors, ......?

the international sticker on the valve cover

[Keith Browning]

I had a run in with a failed pump which I could not attribute any cause to. A fuel sample from the HFCM contained nothing but clean ULSD. The customer and truck had a good service history with us.

 

Here's where it gets interesting. After contacting the Hot Line I took a sample of duel from the fuel test port on the fuel cooler. I got a load of black silt-like debris which we determined was from the failed pump. Somehow the warranty Nazis determined that this was evidence of contaminated fuel when in reality it was not. The pump MAY have been damaged by fuel quality but I could not prove it and neither could Ford as they never called the pump back as the claim was denied.

 

We fought back four times thought the claims process and finally got the claim paid... EVERYTHING in the duel system was replaced and I spent a considerable amount of time flushing the fuel passages in the cylinder heads. If I recall this was close to an $8,000 repair.

 

Moral of the story, be very careful in your diagnosis and more careful in how you word your comments on the back of the repair order.

 

There is a catch though. Just because YOU don't find water or contamination in the delivery system there may be evidence in the high pressure system. We have discussed the subject of Ford denying claims after inspecting the failed pumps and finding water damage - i.e.: rust. You might want to look really close at the fuel lines at the connections and look for rust. If there is long term water exposure those lines will show rust. There is YOUR evidence - inspect and decide wisely.

[walleyewarrior]

We cannot find any signs of rust anywhere or even black in cooler lines, nothing. my conclusion is that the pump failed ,ran shit threw took injecotrs out which in turn took engine out. gave ford all the documentation, they have authorized a drop in complete.

[Aaron]

they have authorized a drop in complete.

You said your prayers last night, didn't ya?

 

[eastendpowerstroke]

they have authorized a drop in complete.

As the sting of having to do a short block and heads on a 6.4L is still fading away...........all I have to say is.........

!!! I HATE YOU !!!

[DieselD]

such headaches...been down this road a few times too.

 

drop ins are nice but dont pay shit! I love how you spend all this time tearing down, inspecting to find the root cause only to not get paid for your time