Friday, December 9, 2022
Powerstroke Injectors

Troubleshooting Guide for Ford 7.3l Powerstroke Injectors


Because the Powerstroke injectors contains several electrical and sensor components that operate together, an improved functionality diagnostic tool must identify any issues correctly. We created this brief guide to assist you in looking for common difficulties and solutions.

However, it is vital to realize that preventative maintenance is critical with diesel engines in general. The most frequent technique to maintain ford 7.3l Powerstroke injectors operating smoothly is to add cleaners to the fuel. However, even if you take every precaution possible, problems will arise.

Now, take out your diagnostic instrument and start working through this checklist.

Check Engine: Stalling/Not Starting

If your engine stalls or starts slowly, you may have a high-pressure oil system leak. If the engine stalls when warm, the fault might be with the snap-to-connect connection on the oil pump, which is a common issue with Powerstroke injectors.

Check Engine: Jerking

If your engine jerks or cuts in and out, it might be due to an oil or fuel pressure problem. Run an injector buzz test and check the fuel pressure.

Check the Oil

To function correctly, the Powerstroke requires a high-pressure oil circuit. Check the oil level to ensure there is enough in the system. If you don’t, this might be the culprit, and simply changing the oil could solve the problem.

Verify Fuel Pressure

If the fuel pressure falls below 45 KPI, the system may have a clog or a leak. Water in the fuel system may easily harm injectors, so look for it. You may need to drain the tank.

Test Glow Plug System

Test the glow plug system to check if there is a problem, especially if you notice white smoke. If the problem is with the glow plug wiring, the diagnostic equipment may not detect it. The resistance between each plug circuit at the glow plug control module and the negative battery wire may be measured to test the glow plugs. If there is no visible smoke, the glow plug system is unlikely to be the source of the problem.

Check for the injector “buzz.”

When performing an injector buzz test, each injector should sound the same; if one differs from the rest, it may need to be replaced.

Look for Smoke Coming From the Tailpipe

If you observe smoke emerging from the exhaust, something is probably amiss with the combustion. White smoke indicates that raw fuel exits the combustion chamber, showing insufficient heat, and no auto-ignition occurs. Because glow plugs generate the heat required to start the combustion process when the engine begins, white smoke — and hence a lack of heat — indicates a problem with the glow plug system.

If you notice gray smoke emerging from the tailpipe, this indicates that oil is burning inside the exhaust. A typical cause of this is turbocharger seal failure. This is frequently accompanied by the smell of oil emanating from the exhaust. In this situation, the turbocharger must be replaced or repaired.

Black smoke indicates that the fuel is only partially burning – there is probably enough heat for the combustion process but not enough air. This suggests that there is an issue with airflow. Therefore inspecting the air filter is a brilliant idea.

Blue smoke indicates that oil is being burnt in the combustion chamber, and there might be a leak in the turbocharger’s compressor section.

Test the Cylinder Contribution

To run the test, pick an injector as if you were going to turn it off manually, but do not disable it. You’ll have about one minute to start the test, and you’ll want to see a straight line in your diagnostic system. If you know the rpm falling, you must replace the injector that is causing the drop.

Verify FICM Voltage

Lower than 45 volts necessitates the replacement of the FICM. Check the power relay if the voltage is zero.

Check Clogs in Oil Cooler

If coolant is blowing out of the degas bottle, the oil cooler is likely blocked and has to be replaced.

Engine Takes Long to Start

One of the most typical adverse effects of a broken line is diluted oil due to too much gasoline. When you first start the engine, it spins over more than average, which is a strong indication that something is happening. This occurs when the injection system has to be re-primed. A prolonged crank time typically implies that the fuel injectors are broken.

While this is by no means a complete list of things to look for when your Powerstroke injector isn’t operating correctly, it does cover the most frequent problems.

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