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Discussion Starter · #1 ·
I have a 2003 7.3 Powerstroke. I had hard starting issues and had to plug the tuck in in summer just to start it. Once started and warmed up the truck ran good. I replaced 4 injectors, 2,4, 1 and 5. The truck now fires right up during cold weather conditions without plugging it in. The problem now is that it smokes really bad. I thought it might be the fuel pump not meeting the demand of the new injectors, so I replace the fuel pump. It still smokes the same. Could it be the injector cups leaking anti-freeze into the fuel?

Thanks in advance!:cool:
 

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Injector cups leak fuel into the coolant, not coolant into the fuel. With the normal fuel pressure being 45 psi and coolant pressure of 16 psi, it's pretty obvious that unless your fuel pressure is below 16 psi, coolant won't get into the fuel. You should check your fuel pressure as a next step. Low fuel pressure can be caused by clogged pickup screens in the tank.

You can tell whether the white smoke is coolant or fuel related by using the sniff test. Fuel related smoke will make your eyes water bit time, and could be caused by an injector with a bad nozzle or one that's drooling fuel.

Where did you get your replacement injectors? One supplier has a real bad rep, with 30% or so of their injectors being bad and needing to be swapped out.
 

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Agreed you need to smell it from a distance,so you don't pollute yourself and get a rockin headache.

How old are your injectors/injector orings that were not replaced? That will do it.

Antifreeze will be white. If a cup was not seated 100 percent before installing the injectors or a loose injector due to not be properly torque, the compression with heat can lift the cup up. A member here had that happened. It allowed coolant to go under the cup and into the combustion chamber. Rare situation but it happened. It put white oil sludge up onto the inside of valve cover. At first site, I had it as a cracked head. Upon returning with my Stant cooling system tester and pulling a couple injectors in that area, I could see thru the injector tip hole in the cup. When I would pressurize I could watch a small stream squirting in. I was extremely lucky to get a view of this.

What was temp in the summer when you had to plug in? If you have good compression, you have good base heat. If you achieve a good cranking speed(minimum 100 rpm), hitting 500 psi hydro, you should light off. There are other factor for starting but those are the biggies for have to plug in in the summer. Unless you have multiple injectors not injecting properly atomized fuel but even then, needing to add to base heat by way of heating up the block because the glow plugs might not be coming on, is often not injectors, summer time anyway. If you have enough not atomizing it won't start and warming the block won't really help. When you turn the key off does the truck rock at the very last moment the engine stops turning? You feel it in the seat?

Go outside. Jump your starter solenoid WITH keys in your POCKET.

Do the compression beats sound even. By that, I mean the time gap between beats, are they the same? Does it sound even?
 

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Discussion Starter · #4 ·
Finally got a chance to respond. Thanks for the reply. The fuel pressure is at 50 PSI with the new pump I just installed. I will confirm that number tomorrow. I also removed the sending unit and cleaned two internal mesh filters. The injectors I purchased were from Napa. Three were they're brand and one was an Alliant (all AD's). It was the weekend and all that was available at the time. The sniff test! It burned my eyes. Am I to assume its not moisture related? This smoke issue started after I replaced the injectors. I have not touched any of the other injectors. It never smoked before. Before I was able to purchase the injectors we would have to plug the truck in all the time, including summer 90 deg. plus temperature. With the new injectors, it fires right up. No problem. Lately our overnight lows have been in the low to mid 40's. I ll start it up by 7 am. (not plugged in). I'll have to get back to with the other test Nick.
 

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I think you've got a bad injector. If you can get hold of an injector cutout box. Use that to cut out one injector at a time and see what happens with the smoke. When it stops that's your bad injector.


If you don't have a cutout box, you can remove the valve covers and carefully disconnect the injector plugs one at a time.
 

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Discussion Starter · #6 ·
Never heard of a cut box. I'll give that a shot as soon as I have a chance. Just another thought! What about the turbo?
Thanks for your help you guys!
 

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Discussion Starter · #9 ·
ok just got in from working on the truck. I removed the valve covers and disconnected each injector connector one at a time. I did notice some difference at times but it did not stop completely. So I scanned again and came up with codes. P1280 ICP sensor circuit low, P1316 IDM code detected, P1248 Turbo boost pressure not detected, P1211 ICP higher/lower than desired (i did unplug this one at times). The codes were inconsistent because I would scan and than clear them. I would come up with or without any. One time when I ran KOEO and a buzz test all injectors showing high to low side open. I did disconnect the main harness one time to remove the valve cover, but how long does the PCM hold that information? My last scan was a P100 system readiness test not complete. P275 cylinder 5 (a new injector) Injector circuit contribution/balance fault. P0284 Cylinder 8 Injector circuit contribution/balance fault. The truck sounds great most of the time and at times will idle rough. When I press on the foot pedal I will get extemely heavy smoke. It seems when the truck idles a bit rough is when the white (grayish white) smoke is more significant.
 

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Wow, your in it ain't ya?

So if anything like what you listed is disconnected while that key is on or engine running, you will get codes. If unplugging injectors while running you will get codes, so this is some of what you see.

This clearing process of " covering the ports" with a towel while cranking was ok PROVIDED the injectors where in place and glow plugs out.
Was that the case?
Let's start there.
 

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Discussion Starter · #11 ·
I'm definitely in it!

In the past when I changed the injectors I would leave just the glow plugs out and turn the engine with the starter and clear out the ports. This time I did it with both the glow plugs and injectors. I also disconnected the harness and fuel pump. It's messy but that's the way I know how. It seems easiest. I thought of draining the fuel rails but I was afraid of stripping the bolt/screw.

The other day when I decided to remove the number 1 and 5 injectors (two of the four new one's) to see if I did anything wrong and I noticed draining in the number 5 port. It very slowly drained down, but what I decided to do was siphon out that port before I turned the starter to clear it. Is that normal?

Today I pulled the #7 injector since it was one of the quietest during the buzz test and inspected the o-rings. It had visible wear so I replaced them and reinstalled the injector. I'll find out in the morning if it helped with the smoking.
 

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I was asking to make sure I was understanding correctly. If that is the case the cylinders reflooded.
If you had enough fluid in there a rod or push rod may have become bent.
You can get an OTC diesel compression gauge and glow plug hole test adapter off Amazon for $100 and change.
I'm not trying to scare you but you need to take a compression reading to eliminate low compression from a cylinder with a bent rod.


Before we get this far, you do know they will smoke after changing injectors until that stuff burns off in the combustion and exhaust components and that takes a few miles, right.
 

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Discussion Starter · #14 ·
I hope its not a bent rod. Should I have left the injectors in when clearing the port? Is it better to use only the glow plug holes? I just went outside to star the truck. Its been raining all day and night. The windows were frozen, so pretty cold out. The truck started up on the first try and is smoking. I'll let it run a while and see if it clears. Will bad o-rings on the older injectors cause smoking? I was gonna change those out too. Any other ideas let me know. Thanks again!
 

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Sure injectors and orings will cause smoke. It will smoke a ton when done correctly as well but it clears after the fuel and oil burn off.

If you have both the injector and glow plug out and you turn the motor, oil is going to come out of rail and into cylinder. IF you did bend a rod the compression lowers and you have this injector spraying fuel into a cylinder without enough compression/heat to proper combust the fuel hence the smoke.

Even if it did flood it depends on how much and where the piston was in the 4 stroke cycle, as to possible damage.

The proper way is to install the injectors, remove glow plugs, rotate crank with ratchet and socket a few complete revolutions, then spin with starter to try to expel some residual.


Let it run and see if it clears
 

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Discussion Starter · #16 ·
I ran the truck about 5 hours for a couple days. It ran good most of the time but the smoke didn't get any better. On those two road trips the truck did loose power and die a couple of times. It seemed to run out of fuel. I was able to get it started again by draining the fuel bowl. The fuel bowl was full and still had pressure. I recently ordered new injector o-rings and will be replacing the remaining three injectors. I had one kit already and was able to replace one of the 4 original injectors. Those were brittle and worn.
 

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Discussion Starter · #18 ·
Sorry I've been busy at work. I haven't had time to work on my truck. The o-rings I replaced on injector 7 were a bit eaten up. When I removed the top one by the metal ring it broke really easy. I just received my new o-rings in the mail for the remaining 3 injectors. Once I get those injectors removed I'll let you know how those are.
 

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Discussion Starter · #20 ·
tried doing a compresssion test but was unable to because of the kit I had (harbor freight). Ill probable have to break down an buy one but money has been real tight lately. For now I changed the remaining injector o-rings and swapped out the ICP with another one from one of my other truck to see if it would make a difference before I spent 185 at the dealership. Nothing good has happened. The truck still smokes like a chimney and runs rough like its running on 5 or 6 cylinders. Every time I take it for a drive it'll loose power and it just dies out after about 3 or 4 hours. I can get it started again if I drain the fuel bowl but it runs really rough. This morning I couldn't start it and noticed my gauges weren't working. I scanned it and the only thing I get is P1275 and P1316. My ICP pressure only gets up to around 780 WOT. I'll replace the original ICP and see if that changes. Could my PCM or IDM be bad? I have already cleaned the socks in the sending unit but I can check it out again. I'm getting 45 psi fuel pressure with the new pump I purchased. Dont know want to do next. I cant afford taking it in right now. I did have a mechanic look at it briefly and he said it was definitey fuel related.
 
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