- Disconnect both Batteries.
- Remove all components to reach your Valve Cover.
- Carefully remove the Valve Cover and Gasket.
- Now High Pressure Oil rail is exposed.
- Remove the Bolts holding the Rail in Place.
- The Rail and the Stand Pipe are held in by the 4 Injectors and O-rings. (Oil will leak out of the rail so place something under the truck to avoid a mess)
- Remove the Rail and Stand Pipe by picking up on it evenly.
- You are at the Injectors now. Unhook the connectors on the outside of the head.
- Use a 19mm 12-point socket and push down on the connector to unclip it from the head. Then push it through the head.
- Loosen the Torx Bolt that holds each injector in place.
- Once the Bolt is removed, the injector and hold-down will come out all in one.
- CHECK TO MAKE SURE THE COPPER WASHER FROM THE TIP OF THE INJECTOR HAS BEEN REMOVED ALSO!!!
- FAILURE ANALYSIS
This step is very important to assure long life from you new Bostech fuel injectors. Below are some pictures representing four common reasons for fuel injector failure.
If your fuel injectors have any of these conditions you should proceed to correct the root cause.
Combustion blow by:
Combustion blow by is normally caused because of a poor seal between the injector chamber and the combustion chamber. This will need to be cleaned. We recommend using solvent and a stiff brush. We do offer a special injector tube cleaning brush. This brush would resemble a bottle brush. Rotunda /owantonna tool part number 303-d112 can also be used. After cleaning use shop towels to clean and dry the injector chamber.
If discoloration in the fuel inlet area between the two orings are present fuel contamination has accured. If this has happened a fuel sample should be taken to determine if the contaminated fuel is still present. If this is the case flush the system to prevent future problems.
Upstream Mechanical Failure:
If you see any signs of metallic material in the injector an upstream failure has acured this is most common form the high pressure oil pump. When this happens an oil system flush is needed and the high pressure oil pump will need to be replaced.
Oil Rail Installation Failure:
This failure is caused by misalignment of the oil rail during an installation or inspection.
- Repeat step 10-12 for each Injector.
- Inspect the O-rings and make sure that One Copper Washer is with each Injector.
- Lube the O-rings on the Injectors with clean engine oil.
- Place pieces of a lintless cloth in the Hold Down Bolt Holes when inserting the Injector.
- Set the Injectors and the Hold Downs in place then torque to Torx Bolts to 24ft/lbs to seat the Injector place.
- After all Injectors are in place, go back around and torque them again to ensure they are at 24ft/lbs.
- Reattach the connectors (you will here them click) and fill each Injector to the top of it with Oil.
- Remove the Stand Pipe from the Oil Rail, place it, and seat it in its place.
- Now line up the Oil Rail over the Injectors then install the bolts and torque them to 96in/lbs.
- Now reverse the removal process.
- Remove the Passenger Side Intercooler Tube and the Oil Filler Tube.
- Remove the Injector Pump plug, and the 2 Glow plug module connectors along with the cable that is attached to the top of the positive battery connection and pull those towards the center of the motor. Also undo the injector connectors at the top of the head.
- Remove the glow plug module. Once that is removed disconnect the "plug" on the passenger side. You will need to slide the red clip over and press down on the tab to remove. Reroute that towards the front of the motor to free up some room.
- Remove the Inner Wheel Well then remove the components to reach the Valve Cover.
- Now repeat the steps for the driver’s side to get to the oil rail.
- Be careful not to break the Injector Plug Sensor while removing the Valve Cover.
- Lift up on the back of the Oil Rail to remove it without the Stand Pipe.
- Once the Oil Rail is out repeat steps 10-12 to remove and install the Injectors.
- Double-check your Torque settings.
- Then reverse the removal process and get everything back together as it was before.
- Reconnect your Battery cables then double-check to ensure everything is as it should be.
- You will need to crank you truck for between 30-60 seconds to regain Oil Pressure in your system.
- Then let your truck idle for a while to purge out any air left in the system.
- Now drive and enjoy your new Injectors.
The Ford TSB 08-26-3 must be performed. The TSB is available from Ford Motor Company or The Bostechfuel.com web site. The TSB explains the re-calibration importance.
TIP to assure long injector life
- Change oil regular.
- Use recommended oil type
- Follow oil guide for temperature in your area
- Change fuel filters before recommended intervals.
- Only use top grade filters
LIMITED WARRANTY CONSIDERATION
Bostech offers a 12 month unlimited mileage warranty on all non commercial vehicles. Commercial vehicles will be limited to 25,000 mile warranty.
Bostech requires that all oe manufactures service procedures are followed. We reserve the right request proof that these have been performed. (e.g. receipt for the procedure)
When injectors are returned for warranty evaluation they will be fully inspected for the above mentions items. The injectors will be fully tested. If injectors are determined to be working fine warranty will be refused. The injectors will be flushed and returned.
NOTICE FOR 6.0 DIESEL INJECTORS!!!
There has been an issue with the 6.0 diesel injectors due to static friction and high oil viscosities. The lower the temperature, the more resistant to flow is your oil; the lower the temperature, the higher the viscosity. Higher viscosities of your oil can cause the injector spool valves to stick. When you start your engine from a cold start where the ambient temperature is less than 70°F, you may experience some of the following symptoms:
- Your engine doesn’t start
- Your engine is hard to start
- Engine exhausting white or blue smoke
- Engine idles unusually rough
- Has no power if you just jump in and drive before the engine warms up
What causes this is when the oil is at a cold temperature, it is more congealed than normal and it could be compared to having molasses in your injectors. These conditions are more severe in colder climates, but can occur at temperatures approximately less than 70°F. The injector coil does not produce enough force to overcome that static friction to engage the injector spool valves. This will cause your 6.0 engine to produce the symptoms listed above.
Common causes that can contribute to these symptoms in your diesel injectors can be easily prevented. Below are a few of the causes of this issue with these injectors:
- Waiting too long between oil changes, causing your oil to be more contaminated
- Using the wrong oil weight (see Figure 2 below)
- Long idle times
- Excess oil in the spool-endcap interface cause the spool valve latching (cold weather)
- Not waiting for the glow plug light to go out before cranking
- Malfunctioning glow plug system
There are many things that you can do to help prevent your injectors from sticking/latching. Replacing your injectors will not automatically solve this issue and you may or may not be covered under the injector warranty. This is not a defective issue. Listed below are some prevention procedures:
- Keep oil changed at vehicle recommended miles
- Ensure that glow plug light has gone off before cranking
- Check to make sure glow plugs are operating correctly
- Do not let your engine idle for long periods of time
- Use recommended oil weight for your engine and correct viscosity for operating temperatures (see Figure 2 below)
- Perform the FICM calibration called for in Ford TSB 08-26-3
If you are experiencing any of the symptoms listed above, injector replacement will not solve your problem. This will only be a temporary fix, if it fixes it at all. The FICM calibration is a permanent fix. It allows your injector coils to very rapidly heat the oil in your injectors to normal operating temperatures until your engine reaches the normal operating temperature. This reduces the static friction in your injectors allowing the injector spool valves to operate as if the engine was already warm, but at a cold start.