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Discussion Starter #1
The new truck has been a trooper, right up until Saturday. I was running from Flamborough to Stoney Creek and did great on the highway until I came off and stopped. Now it's idling rough, misfiring and surging at idle. stumbles a bit while accelerating until about 2000 rpm. Then it seems to clear. Check it out after it cooled overnight. Turbo seems good. Leaking on #2 injector line on the back of the pump. Knew about that before. #1 injector is all wet and seems to be bubbling from where it meets the head. Here's my question: Should I be looking at injectors and seals R/R? or could it be something simple to fix? If the former, is there a good place near Hamilton who would sell/rebuild injectors at a reasonable price?
 

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sounds like you are due for a set of injectors. when I did them in dad's 1990 it was less $$ to buy new than have the old ones rebuilt. they still want your cores though.

dad's truck was an idi 7.3 with the ATS turbo put onto it early in its life, same motor as yours.

we got ours from kw fuel injection in Waterloo , my employer sent our stuff there too. probably more fuel injection places in Hamilton area anyway.

try and tighten down the bubbling injector before you pull everything apart.
your bubbling fuel might just be a return line Oring leaking too, if you have 2 leaking now it might cause the stumbling. once you have it running let it idle and shut it down. check the shrader valve at the filter head and see if it is fuel immediately or has some air first. if you get air first you will have a leak in the suction side of the fuel system.

have seen many dual tank switches leak air into the fuel system and cause erratic problems like this on the idi 6.9/7.3

fixed a neighbors truck once by bypassing the dual tank switch and telling him his rear tank was leaking. he didn't believe me it was the dual tank switch but when I told him the rear tank was leaking and he couldn't use it any more he complied. stubborn old Mennonite :icon_rolleyes: truck went another 8 yrs before he took it to the wrecker.:icon_lol:
 

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Discussion Starter #4
The latest news...Injector 1-loose and return cap rings leaking, 2-ok, line at pump leaking, 3-ok, 4-ok, 5-missing copper seal ring and return cap broken and injector was loose, 6-came out in pieces, I think it was original, 7-ok, a little leaky, 8-I think was also original, copper seal will not come out, I have to re-visit this one, I didn't fix it properly due to lack of a flat reamer. I doubled the washer with one of the old ones and some copper anti-seize in between. I'm not finished yet but if it hauled 3.5 tonnes that way from Windsor, I can imagine what it will do when I finish. I got rebuilt injectors and install kit from Taylor Diesel on Lake Ave. in Stoney Creek for $570 after tax.
 

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used to work on a pile of these at the Ford dealer in 1989-1992. have an injector upper body with the thread removed just for those pesky injectors that that unthread when puling out, I even shaved down the base of another with 2 notches for cleaning out the copper washer mating surface. (almost like a reamer) you did pretty good on this . 2 copper washers isn't a good idea but may not affect anything.
we always put air pressure into the glow plug hole when cleaning out copper washers in the bore.
once they were out of warranty we saw them again........................in 87 Ford offer a 6 yr unlimited mileage warranty on some trucks but it didn't last past 1987:icon_lol:

cheers James
 

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Discussion Starter #6
Installed the new injectors. Runs like a better version of crap. Went through bleeding and looking for air intrusion. Pressure tests and flow tests. The "new" injector pump has "thrown a shoe." Good thing I still have the original. Just need to get it repaired and put back in. Good news found in my adventures. I have a single mass flywheel and nearly new clutch.
 
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