Crazy Smoke and Oil Out of the Exhaust - Ford Powerstroke Diesel Forum
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post #1 of 25 Old 09-01-2019, 06:13 PM Thread Starter
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Crazy Smoke and Oil Out of the Exhaust

I’ve got an 04 F250. Truck has been having some hot start issues over the past month. Replaced ICP, IPR and was still having the issues. So I figured it was injector seals and/or oil rail ball tubes/seals leaking not letting me build pressure. So I was planning on resealing the injectors and rebuilding oil rails this weekend since I had some time off. Well last Thursday truck wouldn’t even start it was acting like the batteries which made sense since they are to the point where they need replaced anyways. So I put them on the charger and drove my car. Friday morning I put the batteries in fires up and back down the driveway, dies right in the road. So I bought new batteries put them in and I’m good to go. Friday evening go to leave for work truck fired right up idling really rough acting like it’s going to die and it stalled. Was able to fire it back up and it’s still idling rough, had no throttle was mashing on the gas pedal and it stayed still ended up stalling out for the second time. Got it fired up again and took it down the street and it had no power, wasn’t blowing smoke, still just running kind of rough. I was able to make it home, it was shifting hard and still running rough the whole way home. Got home pulled injectors, resealed them today. Got everything put back together, fired it up and it’s pouring gray smoke. No blue whatsoever. Just solid gray and I had oil dripping out. Truck was idling rough again and eventually died. Turned the motor over by hand just in case there was excess fuel so it didn’t lock up. Fired it up again and when I went to crank it felt like it was locking up but then would start to crank and fired up. Still was blowing tons of smoke and had oil coming out. What do you guys think the issue could be? I had oil pressure and everything else looked good. Injectors didn’t look bad nothing was super worn. Could some of the injectors be that bad? Or could it be turbo problems or a combination of both?
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post #2 of 25 Old 09-02-2019, 04:50 AM
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As I posted on PSN

I wouldn't keep trying to start it until you know more.
How many miles on the engine and is it an early 04 or late 04?
Is the EGR system still operational?
What did the exhaust smell like? Raw fuel? Any sweetness to the smell?
Any loss of coolant?
Is the oil level low (or high)?
Are the injectors original? How many miles on them?
Do you monitor fuel pressure (aftermarket sensor and gauge)?
Are you confident of your torque wrench calibration when you did the injectors?
Did you blow out the injector hold down bolt holes before installation?
Double check the exhaust and makes sure it is oil and not coolant mixed with soot.

Check for codes with a quality code reader.

You can disconnect the downpipe and see if there is any oil at the turbo.
Might be time to start puling glow plugs to see if any fuel or coolant will drip out of one (or blow out when cranking).
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Last edited by bismic; 09-02-2019 at 06:32 AM.
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post #3 of 25 Old 09-02-2019, 06:00 AM Thread Starter
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Quote:
Originally Posted by bismic View Post
As I posted on PSN

I wouldn't keep trying to start it until you know more.
How many miles on the engine and is it an early 04 or late 04?
Is the EGR system still operational?
What did the exhaust smell like? Raw fuel? Any sweetness to the smell?
Any loss of coolant?
Is the oil level low?
Are the injectors original? How many miles on them?
Do you monitor fuel pressure (aftermarket sensor and gauge)?
Are you confident of your torque wrench calibration when you did the injectors?
Did you blow out the injector hold down bolt holes before installation?
Double check the exhaust and makes sure it is oil and not coolant mixed with soot.

Check for codes with a quality code reader.

You can disconnect the downpipe and see if there is any oil at the turbo.
Might be time to start puling glow plugs to see if any fuel or coolant will drip out of one (or blow out when cranking).
Engine has 196,000. EGR is operational. I pulled the EGR valve and it was dry. Exhaust smells like raw fuel. No sweetness. No coolant loss. Changed the oil before I started the truck. One of the injectors was a Delphi reman. All the others seemed original. I don’t have a constant fuel pressure gauge. I did the blue spring and checked it then and it was good. That was only a few months ago. I did check that the fuel bowl fills up quickly. I cleaned the injector cups and the hold down bolt holes and my torque wrench is good. It is Oil Out of the Exhaust. The other day I got cylinder 7 and 1 contribution codes. After resealing the injectors i haven’t gotten any codes.
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post #4 of 25 Old 09-02-2019, 06:10 AM Thread Starter
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And it’s an early 04.
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post #5 of 25 Old 09-02-2019, 06:36 AM
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Sounds like you have narrowed it down to an injector problem and maybe also a turbo problem.

Be sure to check the oil level again. It could be high with a lot of fuel in the oil. That will potentially wipe out turbo bearings.

IMO pulling the passenger side glow plugs is the place to start.

It would be interesting to know which injector was the Delphi reman.
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post #6 of 25 Old 09-02-2019, 06:41 AM Thread Starter
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Quote:
Originally Posted by bismic View Post
Sounds like you have narrowed it down to an injector problem and maybe also a turbo problem.

Be sure to check the oil level again. It could be high with a lot of fuel in the oil. That will potentially wipe out turbo bearings.

IMO pulling the passenger side glow plugs is the place to start.

It would be interesting to know which injector was the Delphi reman.
If I remember correctly it was the reman was cylinder 1. I’ll start pulling glow plugs now. I was going to just reseal since I was planning on selling the truck and getting an 05-07. But if I’m pulling injectors again I’m building this one out.
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post #7 of 25 Old 09-02-2019, 08:23 AM
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This might be a helpful video:
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post #8 of 25 Old 09-03-2019, 08:32 AM Thread Starter
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So update, I pulled the injectors and separated the upper and lower bodies. The fuel spring on the lower body of the injector is broke on 7 of the injectors. And I pulled the turbo and the outlet and the down pipe are covered in thick oily residue.
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post #9 of 25 Old 09-03-2019, 09:09 AM
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Where were the other injectors bought (or were they the originals)?
How many miles on them?

Last edited by bismic; 09-03-2019 at 12:30 PM.
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post #10 of 25 Old 09-03-2019, 12:08 PM Thread Starter
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I’ve only had the truck for the past 32k miles. But there was the one Delphi injector and then I saw markings on some of the others but didn’t notice a brand and then some have no markings whatsoever.
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