Inspecting Your 6.0L Diesel Injectors – Troubleshooting & Maintenance Guide

Inspecting Your 6.0L Diesel Injectors – Troubleshooting & Maintenance Guide

In this guide: How to diagnose, remove, inspect, and replace 6.0L diesel injectors, covering the most common signs of failure and offering practical at-home troubleshooting tips. 

Overview

  • Purpose: Help truck owners determine if their 6.0L injectors are failing — and

    how to deal with them without wasting time or money.

    Common Injector Failure Symptoms 

  • Typical mileage to watch for issues: 200K-250K miles 

  • Key failure symptoms: hard start or no start, uneven idle or misfire, poor fuel economy, exhaust smoke (black, white, or grey), diesel smell in the cab

    At-Home Troubleshooting Tip: The Temperature Test

    What you’ll need: Infrared temp gun (under $20), Paper & pencil, Cold engine

    Steps:

  1. Start with a cold engine

  2. Shoot temp readings at each manifold port every 1.5–2 minutes

  3. Record 12–15 readings per cylinder

  4. Identify cylinders that heat too slowly or too quickly — these are likely faulty injectors

Safe Injector Removal Tips

Important precautions:

  • Disconnect batteries (48V system)

  • Expect fuel in the cylinder when removing the injector

    - Use a vacuum or squeeze bottle to remove it

    - Failure to do so can cause engine hydrolock 

    Visual Inspection Checklist

  1. Wiring loom: Look for piercings, burns, or broken wires

  2. Pins in connectors: Check for bent, broken, or compromised contacts

  3. Earmuffs: Ensure they are properly attached

  4. Mounting screws: Common failure point; check for breakage or missing screws

  5. O-rings: Look for wear or damage (do not reuse)

  6. Compression gasket (copper):

    - Must be intact

    - Carbon tracking on nozzle may indicate gasket or cup failure

     

  7. Injector tip:

  • Do not use a steel wire wheel (use brass only)
  • Look for cracks, damage, or irregular wear 

Replacing Injectors – What to Look for

Diesel Care’s Remanufactured Injectors:

  • New OE wiring loom with stiction notch for improved cold starts

  • New spool valve — a key differentiator

  • Comes with new o-rings and copper gasket

  • Optional: High-performance nozzles with 40, 70, or 100 HP increases

    Neglect can lead to serious damage:

  • Piston failure

  • Block damage from broken nozzles

  • Resulting repairs can exceed $10,000

    Maintenance Reminder

  • Always replace o-rings and compression gaskets when reinstalling injectors

  • Diesel Care sells complete kits (including oil rail o-rings) at dieselcare.store

    Support & Questions

  • Phone: 1-800-961-9290