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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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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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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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Discussion Starter #4
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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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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Have you tested the FICm and run a power balance?

MikeB
 

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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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Here are the FICM connector face pinouts for a 2004. Assume it is the same as 2003?

Mike B

ficm a.jpg

ficm b.jpg

ficm c.jpg
 

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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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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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Died

I hate it when a thread that pertains to an issue I'm having dies. :doh::shrug:
 

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I hate it when a thread that pertains to an issue I'm having dies. :doh::shrug:
If it's smoking, smells like fuel, and burns your eyes, you're probably dealing with an injector issue that may/may not have damaged a cylinder.

First thing to do is (with keys out of the ignition), disconnect the remote start wire on passenger side and touch it to the + post on the passenger side battery. While the engine cranks, listen to it and make sure it's an even crank with no hiccups or stutters. If you have a flare up on one cylinder (sounds like it speeds up), that's a no bueno. If the crank is even, you'll feel MUCH better about yourself and the engine :grin: Remember to reconnect the wire when you're done.

If you have access to a program like AutoEnginuity or something else that will disable injectors, while it's running and smoking, disable each injector one at a time and watch for the smoke to stop - if it does, note which injector(s)/cylinder(s) you were on. If you don't have access to AE or similar, you can unplug each injector one at a time and accomplish the same thing.

-jokester
 

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ForScan will do the cylinder cutout as well.

Listen to the intake and exhaust for uneven cylinders/leaking valves after you do the crank test as @jokester00 suggested

Wouldn't hurt to remove the oil fill cap while the engine is running and observe the vapors coming out -- should just waft, no puffing or streaming.
 

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Back to life?

Hello out there to "The Great Pacific Northwest" and Central Eastern(ish) US from "The Great Atlantic Northeast" and thanks for the advice.:woot:

New to me truck 6 weeks ago. Previous owner kept good records though and all services were preformed at the recommended intervals.
Reman turbo Nov 2017, other than that no record of parts failures from PO. Just routine maintenance.
I did have injectors #2 & #4 replaced due to bad fuel about 3 weeks ago, but the smell was bad before that and the contribution test after replacement was level and good.
Cranking with the remote start is nice and even.
Blowby with the oil filler cap removed is minimal, really have to look to see anything and very little pressure blowing out.
Running Rotella T6 and Archoil 9100.
No smoke other than a faint white for about 30 seconds after starting below 10F, no smoke even when I romp on it after it warms up.
No decrease in fuel mileage.
No smell in cab while driving.
Truck runs great, starts right up even at sub-zero temps.
No oil in degaus bottle.
Oil level not growing.
I've been running Power Service Diesel Kleen (White bottle) for antigell and am wondering if this could be the cause?
I do have 2 "Pending fault codes" P0069 & P0470 and am unsure if these could cause the PCM to throw the fueling to be out of wack?
Also, the PO deleted the EGR Cooler and EGR Valve so he must have had some kind of reprogramming done?
It's more of an annoyance right now, that's why I've just been reading the various threads and trying to get a understanding of how the various sensors and modules interact...
 

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Is it leaking fuel at the pressure regulator ? You can look in from the front of the drivers fender and sometimes see where these leak. You could also run your hand around the regulator housing, it should be clean and free of fuel.

2:20 shows what the regulator housing looks like.
If it is leaking there you can sometimes smell fuel and all else will seem to be fine. The O ring dies over time.
 

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Just ran out and checked, dry as a bone. The engine compartment is quite clean which makes things easier. The PO took very good care of the truck.
I just put the Blue Spring kit in about 3 weeks ago so I know the O-Rings are good (checked in case I pinched one), but the exhaust had the eye watering smell before that.
 

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It’s easy to conflate multiple issues but as the folks before said if the exhaust has the smell of fuel then fuel is likely in the exhaust. I am no diesel tech by any stretch of the imagination. The contribution test has me confused as I would think it would expose the cause of your issue. What platform was the contribution test run on ?

Please someone correct me if I am off the farm here, I don’t want to lead Xzaviar down some path of futility. But it seems to me that if the vehicle software was correcting for an over fueling injector that with ids when the corrections were turned off the graph would get real wonky and expose a bad injector would it not? Is there other software that shows a graph like ids when the test is run and you can turn the corrections on and off ?

As for the codes it is throwing are these old, new ? Have they been cleared and have returned ? I think @bismic has some experience with these two codes together ?
 

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The place that did my injectors and subsequently the contribution test is a large and reputable place. They use the Ford licensed software to do the contribution test and whatever else they tested for. Like any shop, they're in the business of making money and I believe this place is in the business of making a loyal customer base by providing competent service. I'm sure they dug a little deeper than just the contribution test to insure my truck would be trouble free (and to maximize profit) when they were done and the truck is trouble free, just the exhaust smell. If they could have justified more work based on test results I would think they would have brought it to my attention.
It's not really a fuel smell and I know it's not a coolant smell, it's more of a burning chemical smell.
I filled the truck up last night (22 gal or 3/4 tank) and didn't put any Power Service antigell (white bottle) in the tank to see if that makes a difference, but I only drove a few miles after. I'll know better in a little while, I have to go out later.
The P0069 & P0470 come and go and like I said earlier they are "Pending Faults". On the day they had the truck I checked the faults when I dropped the truck off and they weren't there, of course.
 

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Since you have removed the Cat off the truck, there will be more of a fuel odor than one with the Cat intact. Worse in cold weather as the exhaust pipe cools off more and accentuates the odor. Could also you are over dosing with the additive. Fuel these days is not really Diesel of days past, it is a mix of stuff the EPA is pushing, ...so the station you get the fuel from may be different than the station down the street.
 

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Uh, my Cat is still on the truck. I've only owned the truck 6 weeks. The EGR Cooler has been deleted and the PCM (or whatever) has been flashed so it doesn't throw a fault code. I bought it that way. No way to know if it has any kind of tune on it but there is a spot on the dash where I can tell that something was there with double sided adhesive so a tune might be likely.
I filled up 3/4 tank at a different station the other night and didn't use the Power Service fuel treatment. The smell seems better but still a bit offensive. I'll know better after my next fill.
I'm going to do a new oil cooler and undelete (BPD EGR Cooler) this spring then have the computer flashed back to stock. I know that's kinda backwards for this forum but I will be traveling around the country and want to be legal for the more restrictive states. I think once that's done it'll smell more normal.
I may be way off though.
Spent 6 years as a tractor trailer / heavy equipment mechanic, but that was 30 years ago. These engines are completely different animals today!
 
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