6.0L Powerstroke Injector Install Warning





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.