2002 7.3L running bad - Ford Powerstroke Diesel Forum
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post #1 of 31 Old 05-27-2011, 01:55 PM Thread Starter
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2002 7.3L running bad

Ok here is what is going on. Thursday it broke down on my way to work. I got it towed home after work. Engine seemed to be hydro-locked. But after sitting a few hours here at my house it started to turn over and then fired up. Smoking bad and missing. At about 1500 rpms it starts making a popping sound. I am getting heavy grey smoke that you can tell is very raw diesel smell in it. I did the cylinder contribution test I get cylinder 5 failed. I got a new injector O-ring kit. I just put in stage 1 single shots. It has been running great for about a month since I put the injectors in. I did all 8 injectors. Also it seems like I am getting a lot of crank case ventalation. It is even coming out of the oil dipstick tube.

I am gonna pull the number 5 injector tomorrow. But I am looking for input on any other possibilities.


Also before it died it was smoking grey real bad. I am leaning towards the O-rings or the injector.


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2005 6.0 Crew Cab Long Box Lariat, current truck

2004 6.0 destroyed by contaminated fuel

2002 7.3L burnt
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post #2 of 31 Old 05-27-2011, 04:49 PM
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Yes check the o-rings. But with that much blow-by it's for sure not a good thing. While you're under the valve cover check and make sure none of the rocker pedastals have broken, especially for that cylinder.
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post #3 of 31 Old 05-28-2011, 08:28 AM Thread Starter
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Anyone else have any other ideas?


Your Actions Today, Decide Your Future Tomorrow

2005 6.0 Crew Cab Long Box Lariat, current truck

2004 6.0 destroyed by contaminated fuel

2002 7.3L burnt
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post #4 of 31 Old 05-28-2011, 10:56 AM Thread Starter
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Well yall it is a broken nozzle. Half of the nozzle is missing. Unkown how this happened. I will be dealing with the company I got the injector. I am not blaming anyone things just happen. To many possibilities on how it happened. Did not fully seat, Damaged during shipping, Could have been damaged during assembly, who knows how or why. At this point I am just hoping no major damage to the engine. But I won't know til I get a new injector installed.


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2005 6.0 Crew Cab Long Box Lariat, current truck

2004 6.0 destroyed by contaminated fuel

2002 7.3L burnt
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post #5 of 31 Old 06-03-2011, 06:16 PM Thread Starter
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Well I got the new injector. I got it and the truck is running. But it is failing number 5 cylinder on the contribution test. Also it is missing and I am guessing it is number 5 cylinder missing as well. I also get a good amount of grey smoke coming out of the exhaust on acceleration. I also have what I believe is a good deal of crank case pressure venting out of the oil dipstick tube.

The exhaust does burn my eyes. It is constantly smoking blue/grey color smoke. It is missing cylinder 5, also cylinder 5 is failing contribution test. Yes the injector was installed properly. In fact I even took it back down to the injector just to make sure. I even pulled the injector out and put new o-rings on it just in case as well. But the end result is the same.

I have also changed the oil. I put fresh Rotella 15w40 and a new filter on it.

So either an injector cup or severe damage done to the cylinder or valves from the broken piece of injector.


Oh I can't do your little test with the oil fill cap because of the miss with cylinder 5.


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2005 6.0 Crew Cab Long Box Lariat, current truck

2004 6.0 destroyed by contaminated fuel

2002 7.3L burnt
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post #6 of 31 Old 06-03-2011, 06:42 PM
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pull the head on that side

2008 6.4 f250 lariat 4wd
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post #7 of 31 Old 06-03-2011, 06:46 PM Thread Starter
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Not really wanting to do that. But I think I don't have much of a choice.


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2004 6.0 destroyed by contaminated fuel

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post #8 of 31 Old 06-03-2011, 07:34 PM
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How was the injector that you pulled out of #5? How did the o-ring's look on the injector that you took out?

If the o-ring's were fine then it must have been the injector overfueling that cylinder. And if it didn't have blowby before and now it does then I would have to think that it's messed up the piston. I've seen a piston melted right down from injector issues like this. Looked like someone had taken a torch to the top of the piston. Not pretty.

Sorry, I'm sure this isn't what you wanted to hear. Just curious, where did you get the injectors from?
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post #9 of 31 Old 06-03-2011, 07:36 PM
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Please don't say somewhere on Ebay......

Sorry, just re read your posts and saw the part about the injector nozzle. Yeah, I'd say that piston is done.

That sucks a big one.
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post #10 of 31 Old 06-04-2011, 07:04 AM Thread Starter
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Quote:
Originally Posted by justinmix View Post
How was the injector that you pulled out of #5? How did the o-ring's look on the injector that you took out?

If the o-ring's were fine then it must have been the injector overfueling that cylinder. And if it didn't have blowby before and now it does then I would have to think that it's messed up the piston. I've seen a piston melted right down from injector issues like this. Looked like someone had taken a torch to the top of the piston. Not pretty.

Sorry, I'm sure this isn't what you wanted to hear. Just curious, where did you get the injectors from?
Injector nozzle broke off into the cylinder while driving down the road. The nozzle went somewhere and when it did it caused damage.


Your Actions Today, Decide Your Future Tomorrow

2005 6.0 Crew Cab Long Box Lariat, current truck

2004 6.0 destroyed by contaminated fuel

2002 7.3L burnt
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