Warning: That injector job on the 6.7 Powerstroke took me 6 hours longer than I planned

I ran into a 2015 F-250 last week with a dead cylinder on bank 2. Figured it was just a stuck injector, maybe an hour or two swap. Started pulling the valve cover and found the harness was chafed right where it rubs the glow plug rail. Took me another 3 hours just to find the break in the wire because it only showed on a wiggle test with high pressure in the rail. Had to pull the whole harness and repair it with solder and heat shrink. By the time I got the injector out, the copper washer was smashed flat and the bore had carbon build up. Total time was about 10 hours for what should have been a 4 hour job. Has anyone else fought with those harnesses hiding shorts on the 6.7s?

2 comments

2 Comments

joseph_baker7d ago

Man I'll be honest, I used to think those 6.7 harness issues were blown out of proportion lol. I had a 2014 that I did injectors on twice and never had a problem with the wiring so I figured people were just being rough with them. But then I helped a buddy with a 2016 that had a random misfire at highway speeds and it took us forever to track down. The harness was rubbing against the intake manifold brace of all places and the insulation was totally gone but the wire was still making contact until you hit a bump. That wiggle test you mentioned is the real deal, we almost gave up until I grabbed the harness and gave it a good shake while it was running and the whole truck stumbled. Now I'm paranoid about checking every inch of that harness before I even touch an injector.

wren_jackson7d ago

It's funny how stuff like that works in all kinds of things, not just trucks. You ignore a problem because it's never happened to you, then one time it bites you hard and now you're checking everything twice.