loss of power black smoke on acceleration - Diesel Forum

mcerchio · 10-05-2012, 08:52 PM

Ok f 250 2003 6.0 It started with a shudder at about 50 -55 like transmission shudder, heavy black smoke on aggressive throttle.Prior to this event and oil and fuel filter change have been having what could be described as rough start but smoothes out when warm Ok time to clean egr. Took it out it was dirty. Cleaned out cavity and egr carbon was not damp and am not loosing coolant. Oil was changed (motorcraft filter) apx 500 miles along with both fuel filters (international filter). Ran it like i stole started to clear up then got progressive ly worse. At the end of a 8 mile ride the truck would not move , almost stalled when put in reverse to back in drive way. Last mile thought it might die at stop sign had to give throttle and accelerate gingerly to get going. So i thought fuel. have done blue spring up grade, checked filter and caps and gaskets all check out ok. does not fix. Check FCIM voltage ok in all positions above 47 .8 and higher. Order fuel pressure gauge(isspro electric) install and it reads 56.5(100 psi gauge 4 lines between 50 and 75 it is on first line). this is after blue spring and filter housing checks and I have started and run truck so air should be bleed out. if key is cycled 3 times it will start and idle smooth but press gas and it roughly speeds up and wants to stall on throttle let up. So i replaced the fuel pump and pressure has not changed ,have been picking at for past week and checked codes again and finaly it it throwing a turbo low voltage code. Before today with all sympotms it has not thrown any codes.I am thinking I am gonna try running pump from fuel can to see if any restriction before pump. Tank is plastic. have checked under truck while running and cant see any leakage in fuel lines. Turbo? cause this? still stuck at fuel do to low pressure should be at least 65 right and better with the blue spring. I am lost and ill be dammed before I take it back to dealer that changed out my synthetic oil after told them trans service only nothing else and no flash and couldn't understand why I was furious and was refusing to pay for oil change I didnt ask for. Any help is appreciated

mcerchio · 10-07-2012, 06:58 AM

Ok fed the pump fuel directly from can eliminating tank to pump. No change. Fuel pressure stays steady and engine still rough. Turbo time. Will take it out today if the rain doesn't shut me down

mcerchio · 11-19-2012, 04:24 PM

Ok So i took the turbo out removal on this early 03 was helped along with a stubby 3/8 flex head and six point socket,cleaned and reinstalled per the board(light coat of anti size). That was not the cure. Then a code p0237 turbo low voltage. So I replaced the Map sensor. Truck started still rough idle and loss of power. So if one unneeded part why not two. Replaced the MAF sensor. Restart truck same. Restart again and idles as smooth as ever and power is back. Code p0237 still. Take it for ride still more black smoke on acceleration than normal and notice whitish smoke at idle (Freaking cause of head gasket nightmare) no puking and smell is still all diesel no sweetness to it EGR dry not wet. Take it for another ride running better less smoke Fuel pressure through all this stays steady at 55 or 60 with little fluctuation on hard acceleration or deceleration. Get in this morning and start her up low 40's smooth and let her warm up about 3 min and go to take off and fuel pressure starts fluctuating from 45 to 60. Ride home from work lets it stall. Had mechanical gauge confirm fluctuation of of pressure. Also noticed that with removal of fuel filter cap on engine, less than half inch of fuel in bowl. This does not seem right, it should be full?? I could really use some input please I am trying but not getting anywhere!!!

mcerchio · 11-20-2012, 10:40 AM

Would compression from engine back feed from injector into fuel filter housing cause excessive air in housing and the resulting fuel pressure gauge fluctuation?

Kustrud · 11-20-2012, 01:51 PM

Sounds like you got a lot going on, my thought would be bad injectors/injector stiction. I say this because of the smoke and rough when cold, but you say your EGR vlave is dry (that was my first guess). I would try a 5-40 synthetic oil and some rev x, if that doesnt cure it than its your egr valve/cooler sort of issues. I may be way off but thats my two cents.

dieselmac · 11-20-2012, 05:29 PM

Quote:

Originally Posted by mcerchio

Would compression from engine back feed from injector into fuel filter housing cause excessive air in housing and the resulting fuel pressure gauge fluctuation?

Yes. A bad seal will allow gases around the injectors to the fuel system.

To check, pull the FICM fuse, remove the secondary fuel filter cover, have somebody crank the engine, and watch for bubbles in the fuel reservoir. Bubbles=combustion gases.

mcerchio · 11-21-2012, 10:09 AM

Thanks for the reply's. Plenty of bubble did not go further trying to identify the cylinder figured on removal it will be apparent. Am going to replace copper and O rings on all eight. Hell been without truck for a month now whats a couple more weeks. Part for O rings is 3cz-9229-aa ?? is that what i need times eight? and do i need to do O ring on high pressure oil rail(or is that in the 3cz922-aa kit), could not find correct part number. Also have tried to erase code p0237 but it wont go away. Saw set of 8 injector victor O ring on parts geek or should I stick with motorcraft.

mcerchio · 12-07-2012, 07:03 PM

Ok puled all the injectors and replaced the o rings and cooper gasket. A couple looked questionable nothing really jumped out but no more bubbles. Job was not to bad once u figure out the injector plug. A nice trick is to use a stuby wrench to twist the plug back in just a 1/4 inch turn back and forth till it clicks in. Replaced fuel pump also. This greatly reduced the fuel pressure fluctuation. I took regulator apart and found no o ring behind the black sleeve for the brass spring cup got a new one and viola steady 67psi. Now I still have heavy white smoke acceleration and light at idle. Seemed to run good but not happy about smoke so im parking her. Pull the egr tomorrow if the rain holds off.

mcerchio · 12-08-2012, 06:06 PM

Today I Cleaned the egr was dry not wet. O ring was nicked. Replaced them. Put two new batteries in cause it was a weak crank (three years old) and they are cheaper than the FCIM. Cranked her up after clearing the p0237 and it stayed cleared, the map plug was loose. Idle was smooth fired right up. Power good, boost good, Whitish smoke at idle and black on hard accelerate. Filters all good(air &fuel). Not puking and not loosing any anti freeze. *** I am open to suggestions. Gonna put another 50 mi on her and will be changing the oil and adding rev x. Had a quater tank filled her up just in case. I had the turbo out and did not do the turbo reprogram, should I have?? Or should I just run her hard till it clears up.

nitrogen · 12-09-2012, 09:45 AM

air in the fuel has an equal effect to very low fuel pressure. this can lead to injector plunger scuffing. on my 03 when I had the black smoke under acceleration it generally meant 1-3 injector tips. They can be scuffed enough to show symptoms, but still run quite smooth, and not set any CEL or codes. The only times it showed up is if the tech did the cylinder contribution test after it sat all night. It would show for the first 2-3 minutes, and then it would pass the test.