Failure mode - Ford 3.2L Power Stroke Diesel (Transit 2015-2019)

Common-rail injectors / injection pump faults

Reliability tier: aggregated - verify before ordering, see /disclosure/

Symptoms

rough running / misfire-style shake on a diesel (cylinder imbalance)
hard start or extended crank
MIL with injector-circuit or rail-pressure DTCs
fuel dilution of the oil over time

Compare with the other causes of the same sign on this engine: hard start, long crank or no-start (2 causes) · oil leak, oil consumption or rising oil level (3 causes) · misfire, rough idle, hesitation or surging

Root cause

Common-rail injector and pump-side faults on a small-bore diesel; Ford issued an early injector TSB for nearly-new vans (TSB 16-0099, under 10,500 km) and a low-mileage injector-related SSM (46413). Fuel dilution from regeneration cycles is the owner-documented long-term concern. The low-mileage high-pressure pump replacement itself was Safety Recall 16S32/NHTSA 16V618 (Nov 2016, MY2015-2016 built 07/2015-04/2016: pump FB3Z-9A543-A plus metallic-debris check/flush).

Diagnosis

cylinder-balance test / injector buzz test per the service procedure
rail pressure desired-vs-actual logs; check for dilution (oil level rising)
verify fuel supply (filter, water separator) before injector replacement

Fixes

injector(s) replacement with the calibration/checks per procedure; pump-side repair where the rail pressure fault points there ()

Prevalence

occasional