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Call or Text (352) 722-5295Injectors on the 2008-2010 Ford 6.4L Powerstroke
The 6.4L Powerstroke uses eight piezoelectric common-rail injectors. Each one is actuated by a stack of piezo discs instead of a solenoid, which lets the engine run up to five injection events per cycle: pilot, main and post injections, including the late post injection used for DPF regeneration. They are fed from one rail per bank at up to 24,650 psi by the Siemens K16. That precision is also the weak point, because piezo injectors do not tolerate water or debris. They are unique to the 6.4L, and 6.0L HEUI or 6.7L injection parts do not interchange.
What fails and why
Injectors fail from contamination and internal leakage: varnish that causes stiction, a stuck-open nozzle or a leaking body. The pattern follows fuel quality and how faithfully the water separator gets drained. Symptoms include hard starts, rough idle, misfire, a fuel smell in the oil, a rising oil level and frequent regens. Miss, smoke and rough running usually point to injectors, but the DPF can hide the smoke, so on this truck frequent regens may be the first clue. Fuel trims beyond about plus or minus 10 flag a bad injector. The worst case is a melted piston or hydrolock with no warning light. Cylinders 7 and 8 are the ones most often mentioned, said to see elevated heat during regen, though that pattern is anecdotal.
Stock replacement vs. upgrade
Replace injectors as a complete remanufactured set with new seal kits, not one at a time. Injector seal kits for this engine can include new fuel lines, so check the contents of the kit you choose. For most trucks, stock-flow reman injectors are the right call, because the stock pump and injectors are adequate below about 700 rwhp; larger injectors belong to builds past that point that also run dual K16 pumps. Then protect the new set: drain the HFCM water separator every one to two weeks and change both fuel filters on schedule.
What we carry
- Alliant Power: Alliant Power AP64900 remanufactured 6.4L injector, plus the AP63515 right-side and AP63516 left-side fuel injector wiring harnesses.
- Dynomite Diesel: Dynomite Diesel DDPFD64 injector sets, DDPFD64 stock reman injectors, nozzle sets and the DDPFD64-PINSET nozzle alignment pin set.
- XDP: the XD485 remanufactured fuel injector with line (stock HP) and the XD610 fuel system contamination kit.
- MAHLE: MAHLE GS33555 and GS33688 fuel injector seal kits.
- S&S Diesel Motorsport: S&S Diesel Motorsport injectors listed for the 2008-2010 6.4L.
For other engines, browse the full injectors category.
Fitment notes
Everything here is listed for the 2008-2010 6.4L in the F-250, F-350 and F-450 Super Duty. The Alliant Power wiring harnesses are side-specific: AP63515 for the right side and AP63516 for the left. Match the MAHLE seal kit number, GS33555 or GS33688, to your injectors using the product page. Nozzle sets and the alignment pin set are rebuild components, not complete injectors. Verify by VIN with the fitment checker before you order.
Frequently asked questions
How do I tell which injector is bad?
Fuel trims beyond about plus or minus 10 flag a bad injector, and an injector return-flow test is part of a proper fuel diagnosis. Miss, smoke and rough running point to injectors, but the DPF can hide the smoke, so watch for frequent regens and a rising oil level too.
Do I have to replace all eight injectors?
The recommended approach is a complete remanufactured set with new seal kits rather than one at a time. The Dynomite Diesel DDPFD64 injector set is one way to do that. Check whether your seal kits include new fuel lines before ordering lines separately.
Why did my injectors fail?
Contamination and internal leakage: varnish, a stuck-open nozzle or a leaking body. The pattern follows fuel quality and water-separator neglect, since a plugged HFCM drain lets water through to the K16 and injectors. Drain the separator every one to two weeks so the new set does not see the same water.
Do I need new seal kits with reman injectors?
Yes. Injectors should go in as a set with new seal kits, and the MAHLE GS33555 and GS33688 kits are listed for this engine. Seal kits for the 6.4L can include new fuel lines, so check the contents of the kit you pick.
Not sure what fits? Call the shop at the number in the header, or use the fitment checker on any product page. We install everything we sell.