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The Most Common Issues with Ford 6.0 Injectors

The Most Common Issues with Ford 6.0 Injectors

Replacing everyone’s favorite 7.3L in the 2004 line, the 6.0L featured a new design that was implemented to meet the strict emission regulations. Furthermore, it faced a challenge of maintaining the competitive edge Ford boasted on the international market. The engine was considered cutting-edge back when it was first presented, with a faster turbo response, more advanced features and boasting more power than its predecessors. The 6.0L was the leader in the industry, but the excitement soon faded as the engine kept being recalled year after year.

There’s still no proof that the model year and its reliability are correlated, but one thing owners agree is that the 6.0L is much more unreliable than they’ve come to expect from a diesel engine. Fortunately, the most common issues are easy to find and fix and any issues that appear do so early in its use. Our expert technicians explain how to check Ford 6.0 injectors for problems and how to recognize other performance issues you should be aware of.

6.0L Fuel Injector Control Module Issues

This electronic component is replaceable, but the problem occurs due to issues that tend to cause a premature failure of the FICM component. These issues likely occur due to heat and vibration of the engine. The FICM failure is known to cause issues such as failure to start, hard start, rough running and other stalling conditions. The component can be tested and if need be replaced by a professional. There’s also the option to rebuild the FICM that often yields fantastic results.

Injection Control Pressure and Injection Pressure Regulator Sensor Failure

The Injection Control Pressure or the ICP is in charge of relaying oil pressure in the high-pressure rail. It does so through the use of a sensor, that is known to malfunction. The same goes for the Injection Pressure Regulator or the IPR, located on the rear side of the oil pump. Fortunately, the updated versions of these components have proven to be much more reliable.

Oil Cooler Problems

A known issue with the 6.0L oil cooler is that residual dirt or sand tend to clog and block the coolant side of the part. This poses an issue with many owners, as replacing the cooler is expensive. Furthermore, low-quality oil can also clog the cooler and cause the cooler gaskets to fail. You can diagnose the problem if you find oil in the coolant or the other way around. To make sure this doesn’t happen, change the oil and the coolant as recommended by the manufacturer.

High-Pressure Oil Pump Issues

This swash plate style pump is known to malfunction. Its main goal is to pressurize engine oil but has been known to suffer from leaking seals to full-blown failure. While it is true that the pump is considered a wear item and has to be replaced sooner or later, the problem occurs when you have to replace it sooner, and much sooner than you expected. A good mechanic can use electronic diagnostics to determine whether the pump is operating within specified parameters.

Wire Harness Chaffing

The main cause for a rough start with the 6.0L often lies with the chafing of the wiring harness. It is also known to cause the electrical issues and prevent the engine from starting completely. As the wires vibrate against all sorts of surfaces and components, the lining wears down and they ground out when they come in touch with a conductive surface. To determine if this is causing your problems, follow the wires and try to find chafing along the way. Pay special attention to the areas where the harness is secured tightly.

Turbocharger Lag and Failure

What made the 6.0L different from its predecessors is the Variable-Geometry Turbocharger, or simply VGT, that featured a more efficient design and decreased spool times. Overall, the VGT had much better operating characteristics. However, the VGT vanes tend to get clogged and when this happens the throttle response suffers and the turbocharger takes more time to spool. There are a few solutions to this problem, the first and most obvious being removing the turbocharger for a thorough cleaning. The other is simpler and involves running the engine flat for a brief period of time in order to clear any buildup.
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