[GlennL]

I have a 2003 6.0. The other day i was driving down the highway and my truck starting shaking real bad. after getting off the highway i had no power. at times it would not move after coming to a complete stop and periodically die. I went to one diesel shop and after i said "6.0' the guy was disinterested and sent me to another local "power stroke" specialist (allegedly). I was having contribution codes for cylinders 1,3,7. The guy had his IDS hooked up and his he said he thought it was likely a fuel pump or a copper washer being loose or something to that effect. He said i could leave the truck with him and he would perform further diagnosis, but he said since the whole side all of a sudden went down like that, then it was probably the fuel pump and that he would swap it out for the cost of the pump (factory) plus $100 in labor. So i chose to leave and i went and picked up an airdog 2 from summit. I installed the unit and the truck actually runs way better than it ever did since i have had it. The only problem i have now is that i am still getting a code for cylinder 1 contribution/balance and this thing is smoking like crazy. i get white/gray smoke at idle and stopped and upon acceleration i get black smoke. This thing rarely ever smoked, and only very lightly while the turbo spooled. now its nonstop like a freight train.
So to sum up, never smoked before, installed new pump and now it is rolling white and black smoke and still have a cylinder 1 contribution balance code popping up. i can clear the code but after about 30 seconds it comes right back.

 

[GlennL]

also let me add that i do not think it is the egr/cooler. i am not loosing coolant and i have 4-5 deltas

 

[GlennL]

Pulled the egr. Sooted up, but everything bone dry in the intake. Cleaned the egr. Although I had just changed the oil about 1,000 miles ago I changed it again and did not "fill it up" intentionally. I filled to about 1/2 way on the dipstick. I have googled all day. Tried everything "small". No replies here so I guess it's time to cry and spend bookoo bucks at a shop.

 

[bismic]

You may have low fuel pressure - you need a fuel pressure gauge (every 6.0L owner does IMO)!

Unfortunately the injectors are highly susceptible to damage when the pressure drops below 45 psig. Your symptoms sound like you have already been bit by low fuel pressure.

Sounds like you have an injector dumping fuel. This needs to be corrected soon. Overfueling can cause even more serious issues.

Make sure you use Motorcraft oil and fuel filters and change them at the recommended intervals. Also, International & Ford came out with an upgrade to the fuel pressure regulator spring which takes care of low fuel pressure in most vehicles. If you haven't done the "blue spring" mod, then you probably should.

Get that injector changed (and if you do have low pressure, you may have issues with more than one injector).

Hopefully you cleaned the EGR valve with carb cleaner and not brake cleaner AND you made sure that you did not get any cleaning fluid in the solenoid. Even if you are careful, the cleaner can "wick" up the valve shaft and soften the seal (which lets carbon into the solenoid).

 

[GlennL]

I set the fuel pressure at 60 when I installed the air dog.

 

[GlennL]

I went to another shop this morning and gave them the whole rundown. The guy said that a bad injector will not throw a contribution code. He wants to let it cool down and test the ficm. Seems like every shop has a different perspective and approach.

 

[bismic]

I don't agree with him on the contribution code and the white smoke is most likely fuel, but please keep us informed!

fyi - Ford's guidance for a cylinder contribution code is:

When maximum/minimum pulse width adder is exceeded a fault is set. Cylinder weak due to mechanical problem or injectors are not contributing necessary volume of fuel.

As far as FICM's go, I wouldn't let the dealership install one (if that is in fact the issue). It will cost close to $1k and you still get one that is somewhat prone to failure. FICM repair.com can rework your unit for $450 and it will be MUCH more reliable.

 

[bismic]

I set the fuel pressure at 60 when I installed the air dog.

Do you continuously monitor the pressure (at the fuel rail)? Damage could have been done before you installed the AirDog.

Also, be sure to stick with OEM fuel and oil filters.

 

[GlennL]

As an update I've been here at the shop all day. The diagnosis was that the number 1 injector was bad. The tech that is actually working on it had the "educate" the service manager who was mentioning the ficm. The tech broke down everything and brought me out to look at it. And sure enough the no. 1 injector tip was cracked.
He said it could have been caused by several things but speculation is that since I was having codes on the odd cylinders before I replaced the pump that I probably did have low fuel pressure and that the starvation of fuel heated the tip causing it to crack.

 

[bismic]

You may have low fuel pressure - you need a fuel pressure gauge (every 6.0L owner does IMO)!

Unfortunately the injectors are highly susceptible to damage when the pressure drops below 45 psig. Your symptoms sound like you have already been bit by low fuel pressure.

Sounds like you have an injector dumping fuel. This needs to be corrected soon. Overfueling can cause even more serous issues.

Make sure you use Motorcraft oil and fuel filters and change them at the recommended intervals. Also, International & Ford came out with an upgrade to the fuel pressure regulator spring which takes care of low fuel pressure in most vehicles. If you haven't done the "blue spring" mod, then you probably should.

Get that injector changed (and if you do have low pressure, you may have issues with more than one injector).

Hopefully you cleaned the EGR valve with carb cleaner and not brake cleaner AND you made sure that you did not get any cleaning fluid in the solenoid. Even if you are careful, the cleaner can "wick" up the valve shaft and soften the seal (which lets carbon into the solenoid).

You are lucky if there is no other damage from the injector tip cracking. Does the Tech believe that there was no metal that broke off? That can be big time trouble if it did.

 

[GlennL]

You are lucky if there is no other damage from the injector tip cracking. Does the Tech believe that there was no metal that broke off? That can be big time trouble if it did.

I looked at the injector and did see what looked like a hairline crack all the way across the tip. It didn't appear to be missing material. And the tech was not concerned about broken material (I can understand the ramifications if a part of the tip did break off). I didn't know if the truck had the blue spring or not since I bought it used. So I bought the kit and installed at home (didn't have the upgraded spring btw) I also cranked up my air dog psi to 70. I also removed the plunger in the fuel bowl (it was broken anyway) and removed the filter in the bowl since the airdog filters to 2 microns as well. This was all at the recommendation of the tech. He also said I could delete the bowl, but I am fine with just removing the filter and plunger along with the new spring.

 

[bismic]

Well, there you go. Best of luck.