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Discussion Starter #1
Coming home from camping pulling a 4Klb trailer yesterday, all of a sudden started smoking black - mostly on acceleration or going over mountains. I was in the mountains, 100 miles from home or really anywhere. After initial checks, decided to keep on driving. Temps remained @ normal temps (max 210/221). No power problem, plenty of turbo, and my GPM was as usual for the trip. No loss/mixture of coolant or oil. Starts with no problem but tons of white smoke. No DTC codes. Looks like I burned and blew out what appears to the rolled up corrugated innards of the muffler. My 2006 F350 is still running pretty good.

Pretty sure I cracked or broke an injector tip. Hopefully I didn't ruin my engine. A trip to the local diesel shop is not in the budget. A couple years ago I did a BPD cooler relocate and even replaced one of the injectors. So have bit the bullet and purchased the AE Ford package to hopefully diagnose for the bad injector(s). My plan includes at least running compression tests before injector R&R.Any advice on what to look and test for before expending too much money and effort if the engine may be hosed.
 

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Go ahead and run the AE and report what codes you get back to us. Then we can have a better idea what suggestions to make.
 

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Discussion Starter #3
Initial Testing

Got the AE test software and ran it. Has a P0281 - Cylinder 7 Contribution Failure.
Ran the test to deactivate each cylinder and when all but #7 was disabled, the power dropped. Nothing changed when #7 was disabled (tailpipe still blew white/black smoke).
The balance test showed #7 low @-300 with #1 &#2 @-100, #3 varying from +50 to -200, #4, #5, #6 @0 and #8 @-50. (I replaced #3 5000 miles ago)
All Injectors clicked during buzz test.
FICM runs no lower than 48v.
Smoke is diesel. Doesn't appear to be coolant. No contamination or pressure buildup in cooling system.


I am waiting on compression tester to arrive tonight but probably will be tomorrow.

I am considering to start removing components to get to the injectors.



Any input at this point would be appreciated.
 

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Sounds like you are on the right track. Hope the piston is OK!
 

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Discussion Starter #5
Delays. The cheepie compression tester kit does not have an adapter for the 6.0. OTC has one, but only works with their gauge, so I bit the bullet and bought adapter and guage (total price of 1 injector). Looks like it will be next weekend before I can do the compression test.

I am unable to release the injector plug due to clearance issue with intake manifold (to check the bad injector), so buying the OTC 6766.

Anyone have experience with Injector's Direct vs Lincoln Ford for buying MotorCraft Reman Injectors? I bought one from Injectors Direct 2 years ago and have had no problems (yet only 5000 miles on it). The only concerns was the wire color and spool valve was white instead of yellow - also looks like might have been a smaller gauge. I want real MotorCraft reman components.
 

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I would not buy from Injectors Direct. AutoNation White Bear Lake (on line) and you can get one for $185.

Consider adding on a fuel pressure sensor and gauge. Low fuel pressure can go undetected and ruin injectors.
 

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Discussion Starter #7
Found a tip on removing the injector electrical - use a 12 point 18mm (and not a 6pt like I 1st tried).
So far this project replace 1 or more injectors seems like a lot more work than when I replaced my oil cooler with a BPD relocate kit.
As far as a fuel pressure sensor/gauge, any recommendations. Not that I have had problems and I've already done the blue spring thingy.
 

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The regulator spring upgrade is great, but it doesn't help detecting a plugged fuel filter or a failing fuel pump.
 

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Discussion Starter #9
Number 7 cracked but intact. Lot of carbon in injector sleeve and body.

Compression Test
#7 375 #8 375
#5 375 #6 340
#3 380 #4 340
#1 375 #2 360

Standpipe & Dummy o-rings good. Rail Nipple Cups showing no wear and the o-rings feel good. Got new Glow Plugs and harness. Replacement Injector on order. Sending Oil sample to Blackstone today
Haven't pulled other injectors yet. No suspicion any are bad and look like OEM. Being the truck has over 200,000 mile, these were probably replaced together in past.

Now to decide how cheap to go. Rather than paying for a proper head gasket and APR studs, job I'd rather spend that money and trade-in towards a 5.0 gas F250. But I could take a chance that the truck will last another 15 to 20,000 miles. I only used the truck a couple thousand miles a year, mainly for trailer camping in the white mountains. Nice truck, but at my age, I really don't like tearing it down.

Input?
 

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Chances are good that the injectors are original. No reason that they shouldn't be expected to last 200k+ miles.
 

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Discussion Starter #11 (Edited)
Pulled #8 because it was tested with a minor contribution error a couple years ago when I 1st got the truck. I notice that the #8 lower o-ring is all white, while the one I took out of #7 is actually black with white painted on it - some of which are still left showing on the injector body. Looks like someone replaced the o-ring on #7 sometime in the past. Might as well pull all of the injectors and put in new Motorcraft o-rings.
Note: Found one other with the pseudo want-to-be white o-ring.
 

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Discussion Starter #12 (Edited)
I ordered 1 Injector from AutoNation @ $181 the taxes and shipping added $32 total $213 (Cores are 180 + Tax) Ordered Saturday, got Thur.
I ordered 1 Injector from Injector Direct @ $199. No taxes or shipping (Cores are $100 and I am keeping one for spare) Ordered Tue, got Fri.

Both Injectors are supposed to be OEM Motorcraft. They were identical and I believe to be the real deal. Spool assembly is grey.

Putting it back together with 2 new injectors and new O-rings on the others
 

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Well, I wish you well w/ the injector from Injector Direct. Probably not a problem - especially since you don't have real long term plans for the truck and it already has quite a few miles!

The key with a remanufactured injector is who does the remanufacturing, not so much whether they start w/ an OEM core (and although a quick visual inspection is always good, it is hard to tell much without a teardown).

Ford uses Pure Power to rebuild the injectors (used to be Siemens, but Pure Power is a spin off company of the Siemens and International joint venture). They do an exceptional job. According to their advertising, it certainly does look like Injectors Direct sells the same part as what you would get from Ford (one of their 4 options), AND they seem to sell the brand new ones (only produced by Pure Power).

Searching for feedback on them generally looks good, but there are some bad experiences out there also. Thing about parts like injectors though - success is not something determined in a year or two.
 

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Discussion Starter #14
It's Alive

Took a 40amp charger and 6 minutes of cranking. Sounds pretty and maybe a bit quieter. No smoke. I will probably road test tomorrow after I finish putting everything back.
 

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Sounds great. Give us an update after the road test!
 

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Discussion Starter #16
Did 20 miles at various speeds and acceleration. After about 5 miles, truck stopped smoking except when I put the pedal to the metal and then just got a quick black puff. The engine hums when running and idling. Starts right up. A tick while idling I was hearing before no long exists. Temps normal. AE Balance test - almost a flat line for all cylinders. No codes thrown.
Looks like I am going to keep the truck a little while longer. Guess I better go and wash the truck now and get ready for another camping trip to where it is cooler than here.
 
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