3rd Gen Engine and Drivetrain -> 2003-2007 5.9 liter Engine and drivetrain discussion only. PLEASE, NO HIGH PERFORMANCE DISCUSSION!

injector failure / valve cover gasket failure -06

Old Jul 17, 2015 | 11:05 AM
  #1  
IPDiesel's Avatar
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From: Calgary, Alberta
injector failure / valve cover gasket failure -06

I have been randomly getting a code p02146 & p0202. Its basically saying that injector 2 failed/misfired.

the truck will restart fine, and I clear the codes and everything seems fine for 4-6 months.

The good ol interwebs says that it can be the injector gasket, or a failed injector. But as it is an intermittent failure, its really hard to diagnose without throwing parts at it.
My price at a dealer for an injector is 730, and the gasket is 370. Little pricey to play trial and error.

I spoke with an ex diesel mechanic who used to work at a dealer- he said it was a injector failure for sure-but many others disagree.

Visually, everything looks fine. Voltage is good on the batteries.

Truck has 185k on it ( 2006 5.9)

got any ideas?

I'm not really interested in changing the injectors out to higher HP versions ect- its just a daily driver.
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Old Jul 17, 2015 | 06:02 PM
  #2  
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From: Antioch, Ca
I'd ohm out the injector harness and each injector directly. Injectors should read less than 1 ohm.
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Old Jul 17, 2015 | 09:32 PM
  #3  
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i have just been told the same thing on my 07 ,5.9 bad injectors and the ohm test while running not so warm showed way more than 1 ohm , the mechanic saying replace them all ,i said not financially possible ,so we decided on getting more testing when the engine is hot , also the problem i have heard from a few very good diesel mechanic is that after market injectors are just too risky to buy,most say you get a 80% chance that they are good and its the 20% that cost you to fix
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Old Jul 17, 2015 | 11:32 PM
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From: Southern Idaho
You can get valve cover gaskets for less than $200 and a set of brand new bosh injectors for $2000. Connector tubes for under $160. Stay away from the 6.7 tubes.
Before you replace the injectors, do a return rate test to see if you need them and also ohm them, as said earlier.
Waiting for one to stick open and ruin your engine is a $12,000 option also.
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Old Jul 18, 2015 | 10:05 AM
  #5  
carl48's Avatar
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From: ruidoso new mexico
you can just replace the solenoid without removing the injector, it only takes about 20 minutes total time. i think the wire nuts are 8mm and the deep socket is 1 1/8". there is two different suppliers on the internet, i have used both of them. if it is over 1 ohm it will be intermittent this was a design flaw on how the post's were connected to the coil, they used a wedge pressed into a split ring for contact, i cut one into at just the right spot to be able to observe the fault.
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Old Jul 29, 2015 | 09:57 PM
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From: Pacific MO
I have a 2004 that is all of a sudden dumping fuel into the crank case. I was told that it was a cracked injector housing. Called Diesel Injection Systems in St. Louis, MO and they told me 315 per injector.
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