Update and fix (almost) 03 smoking bad, no power, hard starting, stalls - Ford Powerstroke Diesel Forum
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post #1 of 2 Old 12-04-2012, 01:26 PM Thread Starter
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Update and fix (almost) 03 smoking bad, no power, hard starting, stalls

Update for those wondering. Bought a project 03 4x4 extended cab with 136,000 miles. Truck was sold to me with 4 new oem injectors and$5500 in repairs 500 miles prior including new heads, oil cooler, and egr delete. Owner had enough of it when 500 miles after the repair it was smoking bad, hard starting, very low power, and no boost wouldnt go over 35 and would not shift. He stated it needed another set of head gaskets as it did the same thing as before the repair.

I tore it down after testing the FICM which tested good. Could not find leaking head gaskets when torn down. I replaced with OEM HG, studs, new injector orings, OEM oi filter and fuel filters. Truck ran same as before.

I suspected possibly plugged cat, pulled off the cat and it was plugged solid. Cat is gutted now. Ran good with out it but had a miss. Unplugged exhaust back pressure sensor and that cleared it up. Replaced EBS and IPC due to it leaking. Pulled IPR and check it and cleaned it. Truck ran really good but still smoked very heavy. Took it for a 5 mile test drive and it lost boost, and squealed from the turbo, broke the turbo shaft in half on the test drive. Ordered a used turbo, installed it and it runs great smoking stoped except at an idle and at start up. Exh had a lot of oil in it.

Ok so now after all that I have light white/grey smoke at an idle only, stops when reved up or driving down the road. Also smokes a bigger puff on warm start up. EGR is gone and so it the cooler. HGs are new no puking. No codes, Ran a power ballance with the AE and it is good and turning off injectors is no change in smoking and each cylinder drops the same RPM. No miss, smooth idle. No bubbles in secondary fuel filter when cranking. I suspect it has a bad or leaking injector in one of the 4 old ones. Luckily thay are on the drivers side. Wondering if I should pull them and send them out for testing at $35 each or drive it for a bit and see if it gets better or worse?
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post #2 of 2 Old 12-04-2012, 01:32 PM
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Since driveing it for awhile shouldn't cost ya anything drive it and see if it clears up.

Lord I shall lead them to the water but I will not try to make them drink
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