Black smoke, diesel from tailpipe - Ford Powerstroke Diesel Forum
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post #1 of 13 Old 08-15-2017, 07:12 PM Thread Starter
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Black smoke, diesel from tailpipe

Well, the wife & I were,headed to the North Carolina mountains for the solar eclipse. I had to work until 7, so she took the loaded truck and headed out earlier. I obviously missed a couple of calls from her while working and when I did call back I got the following story-

Coming down into Clayton, GA she noticed smoke in the mirror and the engine began to run rough. As she got closer to the destination the smoke got heavier and the engine continued rough and as she describes "noisier than usual".

I left work early and got there just before dark. Obvious signs of liquid having come from both the tailpipe and the muffler, smells like diesel. As it was getting dark I decided no troubleshooting for the night.

Truck is a 2004 (early 04 with 2003 engine). In its life it has had the following repairs/mods (if my old addled brain can remember them all)

New stock FICM AT 800 miles
Reman turbo under warranty
FICM Repair FICM with Atlas40 tune
D.C. power high output alt
8 injectors replaced with the newer stock design
Sinister EGR delete
New HPOP
New oil cooler
Blue spring mod
Coolant filter

Oil changed religiously every 5,000 miles with Rotella. Fuel filters changed every 15,000. OEM filters only

What now? Stuck injector maybe?

I love the truck, but I need to be confident in its towing ability....

Just outside Franklin, NC now. Anybody heard of "Diesel Performance" in Franklin?

Last edited by tim5055; 08-15-2017 at 07:24 PM.
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post #2 of 13 Old 08-15-2017, 07:38 PM
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Sorry to read. Yes, I'd expect an injector and be looking for contribution/balance and compression checks. Use extreme caution driving it.

Can't help with your nearby diesel shop. There's a BPD installer about 90mi away in Greenville. Depending upon what you see locally, it may be worth the mileage charge to get it to Greenville.

Good luck getting it situated.

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BPD oil cooler relocation and upgraded EGR cooler (spooled), BPD oil bypass filtration, aFe Magnum Force CAI, Mishi radiator, 7.3L fan clutch, EC1 ELC, XDP coolant bypass filtration, '08 trans pan/filter, PTP direct clutch solenoid, blue spring, 6.4 starter, MBRP y-pipe, BD boots/clamps, '05 intake elbow, ccv reroute, Torque Pro + OBDLinkô LX, Autometer EGT
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post #3 of 13 Old 08-16-2017, 10:45 AM Thread Starter
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Originally Posted by djmaguire View Post
Sorry to read. Yes, I'd expect an injector and be looking for contribution/balance and compression checks. Use extreme caution driving it.

Can't help with your nearby diesel shop. There's a BPD installer about 90mi away in Greenville. Depending upon what you see locally, it may be worth the mileage charge to get it to Greenville.

Good luck getting it situated.
Thanks

Rather than attempt a drive, I decided AAA was due to tow me. It's in the shop now. From the sound of a start attempt only plus the diesel in the exhaust system he says he thinks one cylinder is filled from a stuck injector or split injector "O" ring.

Time & money will tell the whole story......
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post #4 of 13 Old 08-16-2017, 05:07 PM Thread Starter
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Well, not good news. Once they got it inside #5 has less than 100psi compression. Looking at a long block from Asheville Engine......
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post #5 of 13 Old 08-16-2017, 05:41 PM
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Well, not good news. Once they got it inside #5 has less than 100psi compression. Looking at a long block from Asheville Engine......
Ouch. It'll be nice when it's all done, though. Very.

2004 F550 CC Lariat
BPD oil cooler relocation and upgraded EGR cooler (spooled), BPD oil bypass filtration, aFe Magnum Force CAI, Mishi radiator, 7.3L fan clutch, EC1 ELC, XDP coolant bypass filtration, '08 trans pan/filter, PTP direct clutch solenoid, blue spring, 6.4 starter, MBRP y-pipe, BD boots/clamps, '05 intake elbow, ccv reroute, Torque Pro + OBDLinkô LX, Autometer EGT
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post #6 of 13 Old 08-16-2017, 06:11 PM
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You may want to get in touch with @kcoyner . He has an Asheville engine. Real happy, as I recall. He might have some insight for you since he's been through it before.

2004 F550 CC Lariat
BPD oil cooler relocation and upgraded EGR cooler (spooled), BPD oil bypass filtration, aFe Magnum Force CAI, Mishi radiator, 7.3L fan clutch, EC1 ELC, XDP coolant bypass filtration, '08 trans pan/filter, PTP direct clutch solenoid, blue spring, 6.4 starter, MBRP y-pipe, BD boots/clamps, '05 intake elbow, ccv reroute, Torque Pro + OBDLinkô LX, Autometer EGT
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post #7 of 13 Old 08-16-2017, 06:28 PM Thread Starter
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You may want to get in touch with @kcoyner . He has an Asheville engine. Real happy, as I recall. He might have some insight for you since he's been through it before.
Thanks

I've got,a friend here in the mountains who lost his 6.0 about a year ago. I did the research for him and he went with Asheville on my research/advice. He has been very happy, except.......

The mechanic (same one who has my truck) r commended a new HPOP while it was open. He didn't go for it and now a year later he had to replace it.

I'm figuring while it's apart new HPOP, water pump and at least thermostat. Anything else?
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post #8 of 13 Old 08-16-2017, 06:59 PM
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Yes to HPOP. Especially your year.

Ya know... you could go crazy with upgrades. I'd do a y-pipe on principle. Prolly IPR and ICP for the same reason. You already have the water pump in mind. Good plan. Everything else is pretty easy to get at. Hard to say.

So... Your friend's 6.0 died in the same place and ended up at the same mechanic? Where is this Bermuda Triangle for 6.0s again?

2004 F550 CC Lariat
BPD oil cooler relocation and upgraded EGR cooler (spooled), BPD oil bypass filtration, aFe Magnum Force CAI, Mishi radiator, 7.3L fan clutch, EC1 ELC, XDP coolant bypass filtration, '08 trans pan/filter, PTP direct clutch solenoid, blue spring, 6.4 starter, MBRP y-pipe, BD boots/clamps, '05 intake elbow, ccv reroute, Torque Pro + OBDLinkô LX, Autometer EGT
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post #9 of 13 Old 08-16-2017, 07:20 PM
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Get 05+ icp sensor. If your mechanic friend has an 04+ intake manifold I'd highly advise changing that too. Get rid of 03 intake. In case, in the future if hpop cover has to be accessed intake can stay on.


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post #10 of 13 Old 08-20-2017, 05:48 PM
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You may want to get in touch with @kcoyner . He has an Asheville engine. Real happy, as I recall. He might have some insight for you since he's been through it before.
Yes I'm very happy with my Asheville Engine. I have almost 60K on it now and I've done nothing but change the oil and filters. I purchased the Performance 20 with the Stage 2 Cam.
While the cab was up I put on a BPD remote cooler, a KC Stage 1.5, a regulated return, and a few other goodies. Injectors were almost new from the old engine. A short time after that I replaced the FICM with a BPD and tuned it to Atlas 80. I'm at 284K now and my HPOP is still going strong.

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