6.0 smokes, burns eyes, runs good. no codes Help - Ford Powerstroke Diesel Forum
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Old 04-16-2013, 08:23 AM
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6.0 smokes, burns eyes, runs good. no codes Help

Help, have a 03 6.0 with 130,000 miles. Truck smokes when idling/fast idle grey color, smells like fuel and stinks like fuel burns your eyes. No codes on the AE, power balance looks good on the AE as well. Runs and starts good. Turns over good but I suspect a possible leaking injector. Turbo has been replaced and was bad also, and it had a plugged converter that is removed now. Truck does not smoke blue like it did with the Turbo bad. EGR has a block off kit and the cooler is removed. Oil cooler replaced, ICP replaced, EBP replaced both sensor were bad. I did not see bubbles in the filter housing when testing. I put all new orings and copper seals on the injectors when I replaced HG and torqued then to spec. 4 of the injectors are ford remans. I pulled the manifolds and ran it to try to find a smoking cylinder, drivers side looks clear and not burning eyes bad, passenger side all the cylinders look similar with light smoke, but they do let out a spark now and then out the heads when running. Driver side has no sparks. Smoke burns your eyes very bad and you cant hardly breath like fuel.

So since I can confirm that it is the passenger side, what now. I cant really find a cylinder that smokes a whole lot worse than the others. Possibly the second one smokes more but its really hard to tell. I suspect fuel since it burns your eyes so bad. What could cause the whole bank to be smoking, over fueling. Do I have a leaky injector possibly. Do I pull the injectors and have them tested? Where do I go now. No other problems other than smoking bad and burning eyes? Can the dealer run a better power balance than the AE? I'm at a loss. Help!
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Old 04-21-2013, 04:40 PM
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Update, checked for bubbles again in the fuel filter housing and nothing. I pulled the 4 injectors in the bank that it smokes from and did not see anything alarming. I have talked to a ford diesel tech and a international tech and neither have an idea. The ford dealer did not want to waist my money trouble shooting it. I am going to look for some place that can bench test the 4 injectors I pulled out to rule them out. All four are recent ford reman injectors. I have new heads, oe gaskets, studs, egr delete kit, oil cooler replaced, turbo replaced, icp replaced, ebp sensor replaced. The degas bottle hold pressure for days. I get grey/white smoke that stinks like fuel bad and burns your eyes but starts and runs great, good power too. Smoking seems worse when its warm and at idle. So far I have stumped every one. What would make it smoke on one bank?
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Old 04-21-2013, 05:07 PM
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The AE should give you very good results for the contribution test. You further test seem to move it to a possible nozzle issue. I say that because if it was a larger problem it would continue to show at higher load or pressure. As well, it could be a spool valve that isn't behaving, but that would usually show up as a contribution or balance issue.
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Old 04-23-2013, 05:57 AM
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Sent my Injectors for testing

I sent 4 of my injectors from the left bank into Huckstorf Diesel Pump & Injector Service, Inc in Franklin WI for testing yesterday. Testing costs $35 a piece. I am crossing my fingers they find a bad injector. These injectors are about 2 years old Ford OEM remans, but one does show signs of leaking past the copper seal on a tear down before this time. All were sealing good this time. Maybe its possible previous combustion leaking past the copper seal did injector damage to this injector or another in this bank. That being said all 4 were sealing good this tear down. Should know later today the test results.
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Old 04-23-2013, 04:31 PM
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Back to the drawing board, all 4 injectors test really good, no problems... they are shipping them back. Only recommendation their tech had was to have the truck flashed with the newest update.

Question does the FICM have a circuit for each bank? Just wondering if it could be a bad board in the FICM causing the smoking and still start and run good. FICM does test good for power.

What else could possibly cause smoking? Worse when warm. Grey and stink like fuel burn your eyes? I have to be missing something? Anyone?
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Old 04-24-2013, 05:19 AM
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Have you tested the FICm and run a power balance?

MikeB
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Old 04-24-2013, 07:38 AM
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The FICM does not work on eack bank specifically. I don't have the grouping in front om me, but it would be an easy search to get the groupings. IIRC, each FICM harness plug works in alternating fire order.

Did any injector have any difference in tip colour or carbon? That might give you a clue as to which cylinder is the problem. It is either the FICM or a valve not closing properly, assuming the injectors are truely good. You really need to run the balance test as I mentioned earlier.
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Old 04-24-2013, 08:04 PM
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Here are the FICM connector face pinouts for a 2004. Assume it is the same as 2003?

Mike B

6.0 smokes, burns eyes, runs good. no codes Help-ficm-.jpg

6.0 smokes, burns eyes, runs good. no codes Help-ficm-b.jpg

6.0 smokes, burns eyes, runs good. no codes Help-ficm-c.jpg
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Old 01-15-2014, 08:50 AM
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Having exact problem with an 07, 115,000 miles, did you figure this problem out? This truck is also all stock.
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Old 01-15-2014, 09:07 AM
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I had this problem last year and mine ended up being a bad injector (#8) under the degas bottle. It ran great everything was doing fine but smoking grey smoke like crazy. Replaced the injector and never has done it since. I'd check the other injectors to make sure one of them isn't bad.
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