Ford 6.0L Power Stroke Remanufactured Injector Comparison Kit

Coil Assembly

  • Motorcraft replaces the entire coil assembly with a new assembly. This is important to prevent wire fatigue and poor cold starting.
  • The competition re-uses coil assemblies (connector seals, wires, and wire guide are not replaced). In addition, pin alignment and conductivity is not verified when re-used.

Coil Assembly End Caps

  • Poor cold start performance can be a result of “stiction”. “Stiction” occurs between two precision ground surfaces when a thin film of oil is present creating a hydraulic lock between the two surfaces.
  • Motorcraft patent pending technology features an end cap with a vented slot to prevent this “stiction” condition. This vented slot ensures smooth engine performance in cold starting conditions.

Disk Check Assembly

  • Disk check assembly high pressure sealing surfaces are refinished to original specifications (All eight sealing surfaces are machined).
  • Sealing surfaces are critical to the operation of high pressure fuel systems with injection pressures reaching 20,000 + psi.
  • Motorcraft OE specifications maintain less than 2 microns* deviation from perfect surface flatness which assures fuel injector long life, high mileage, and reliable performance.
    • *For comparison purposes, a human hair is approximately 74 microns.
  • Many competitors do not refinish sealing surfaces and for those who do, the surfaces are refinished in a non-circular pattern. Both of these approaches can create leakage paths.

Control Valve Body & Spool

  • Both the control valve body and spool are precision ground to Ford specific diametrical tolerances for sealing and directing oil which results in optimal injector operation.
  • All spools are replaced with new spools and machined to the existing control valve body. Competitors re-use old spools.
  • Motorcraft includes the following new components:
    • Rail connections
    • Thru-rod, nut and belleville washers
    • Coil’s and wiring harness
    • Spool
    • “O” rings
    • Springs

Intensifier Body & Plunger

MotorcraftCompetition’s Plunger
The intensifier body and plunger are precision match honed to
operate at extreme pressures and temperatures.
Competition reuses the plunger. Reused plungers
experience coating loss which can result in internal
injector leakage.
Motorcraft uses all new plungers to assure durability
and reliability.

Nozzle Assembly

  • All remanufactured nozzle assemblies are chemically treated and micro brushed to remove carbon and fuels prior to inspection and test.
  • Seat radius scrubbed for proper sealing to cone nut.
  • Each nozzle is flow tested to ensure proper injector performance and emissions.
  • Orifice holes inspected 100% for acceptance criteria.
  • The nozzle serial number is another example of the quality control processes in place to ensure Motorcraft remanufactured fuel injectors meet OE specifications.
  • All remanufactured nozzles that do not meet Original Equipment specifications are replaced with new nozzles.

Non-Motorcraft Nozzle Assembly Analysis

  • Competitor’s nozzles failed flow, leakage, needle lift, overall length, and valve opening pressure.
  • Failing Original Equipment injector specifications can lead to high carbon build up with nozzle coking, potentially “washing down” of the cylinder wall as well as crankcase dilution resulting in emission problems, and poor performance.
TestPerformancePass / Fail
Flow Volume:553.41cc – 568.78ccFail
Leakage Rate:0.33cc – 0.37ccFail
Max Needle Lift:267.8mm – 291.55 mmFail
Overall Length:-0.150mm – -0.250mmFail
Valve Opening Pressure:-2.4 bar – -4 barFail

Motorcraft Competitive Advantage Summary


Injector Component*
MotorcraftCompetitionMotorcraft Benefit
Coil AssemblyNewUsedNew coil assembly prevents
wire fatigue and poor starting.
Coil Assembly End CapsUses end cap with
vented slot to prevent
“stiction”
Not AvailableVented slot ensures smooth
engine performance in
cold start conditions
Disk Check AssemblyHigh pressure sealing
surfaces are refinished
to OE specifications
Does not refinish or laps sealing serviceMaintaining less than 2
microns of flatness assures
injector long life, high
mileage and performance
Control Valve
Body & Spool
New spoolsUsed plungersOptimal injector operation
Intensifier Body
& Plunger
Precision match
honed New plungers
UsedGreater durability
Nozzle Assembly100% flow testedNew flow testedFlow testing ensures
proper injector performance
and emissions

Jimmy Finch

Dallas Branch Manager, M&D Distributors

Jimmy Finch has over 33 years of experience in Diesel Engine Sales, Service and Repair. His experience started early in life at Texas Fuel Injection Service (an early acquisition of M&D) as a job with a means to an end. Somewhere in that 33 years this job turned into a fulfilling career. He started in the injector clean up department and has held practically every position leading up to his current role as Branch Manager of the Dallas, Texas location.

In his spare time, Jimmy enjoys spending time with his wife of 24 years, Priscilla. They are currently getting ready to make their way into the empty-nesters stage of life. He also enjoys the occasional hunting trip with friends and family and chasing down potential customers by the names off their trucks.

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