6.0 BLOWING BLACK SMOKE!!! HELP!!! [Archive] - PowerStrokeNation : Ford Powerstroke Diesel Forum


05-14-2012, 01:43 PM
No it is not by intention or anything else in that manner. But my 03 6.0 is blowing black smoke out of the exhaust like a over fueled 7.3 with a straight piped exhaust. Started this weekend while pulling a load (Not even a big one) just a 12 foot flat bed trailer with about 3,000 lbs of brick on it. Any way the reason i even noticed in the begining was by looking the mirrors and realizing that smoking every one and anything out behind me. A quick look down all gauges were in the norms. Not even a check engine light. Only issue i was having with the rig was a rough idle with it in gear. Truck made it home smoking the entire way needless to say. I start to tear into the engine sunday, first theing i noticed was soot all over the top of everything in front of the turbo, i pull the intercooler pipe, boost boots, and realize that there is oil or something inside of them. PLEASE HELP ME OUT HERE!!! i have no clue what this might be and have been regulated to riding my motorcycle back and forth to work which would be no big deal if i was still stationed in california, but here in ohio the rain is coming and no one likes to get that wet on the way to and from work... I am just looking for area's to start looking at more closely before i rip all the way into this thing... Thanks for any help

05-14-2012, 01:55 PM
Pull your EGR valve and take a look at it and inside the manifold.

05-14-2012, 01:55 PM
Do you have AE?

05-14-2012, 01:58 PM
The oil in your Inter-cooler pipes is due to the crack-case ventilation system. A CCV reroute will take care of that. it basically dumps oil mist from your valve covers into the intake. It sounds like your turbo may be shot or going to be dead very soon. Any shaft play? do you have a boost gauge to check?

05-14-2012, 02:53 PM
CCV reroute wont do anything for this man.

Pull your EGR valve. Is it wet?

05-14-2012, 07:37 PM
Will pull the EGR valve out tonight after work, and the turbo as well. Take it i am looking for crap inside of the EGR valve, looks like the delete will be coming sooner than i thought and the turbo oh geeze, are the stockers rebuildable on this truck? Just looking for a cost effective IE within reason fix to the issues at hand. Can not afford a full rebuild with power adders at the moment...

05-14-2012, 08:15 PM
Oh just a quick question as well how would either of those produce exhaust soot and leaks in the engine bay? Please excuse my ignorance just wondering is all... Reckon this is going to be one hell of a learning curve...

05-14-2012, 08:49 PM
When my egr went bad it didnt black smoke at all... so idk what the point of pulling the egr would do. Sounds to me your turbo is just leaking oil and you exhaust is burning it.

05-14-2012, 10:55 PM
Burning oil is blue smoke not black.

Bad exhaust leak in the upipes? Are you making any boost?

05-15-2012, 09:05 AM
Did you put on a new down pipe when you did your exhaust? I would go through and retighten all of the new exhaust clamps. If you did put on a new DP then I would also make sure it seated right.

05-15-2012, 02:01 PM
If the turbo is shot, the truck wouldnt make black smoke... The computer is smart enough to not dump fuel when there is not enough air. The question is why is there more fuel being dumped and a rough idle.

Personally, I would check IAC (idle air control), and TPS (throttle position sensor) first. Get that out of the way, then move on to bigger things. Start simple.

Just to make you feel better, The stock turbo is rebuildable if its bad (I dont think so) Also, they are extremely easy to do. It usually takes me 1.5-2 hours to fully rebuild a turbo from start to finish including sandblasting and cleaning. Ive done 10 or so with no issues, so I feel confident anyone can do it as long as you have an expanded view to follow for your first couple tries.

05-15-2012, 02:52 PM
Did you throw any codes? And do you know what your boost is? I would also check your intercooler pipes/connections for holes or tears. As well as your air filter. might just be an air issue.

05-15-2012, 02:55 PM
Just saw you said you DID check the IC pipe and connections. They will have a little oil in there, like someone else said to get rid of that just a simple CCV mod but thats not your issue.

05-15-2012, 03:09 PM
When my egr went bad it didnt black smoke at all... so idk what the point of pulling the egr would do. Sounds to me your turbo is just leaking oil and you exhaust is burning it.

When my EGR valve stuck open it idled but a little rough and when I tried to drive down the road it made a ton of black smoke and felt like it was firing on two cylinders.

05-15-2012, 10:55 PM
X2!! tons of smoke and no power

05-16-2012, 02:23 PM
It will idle although very rough sounding and shudderring. It smokes regardless of moving under its own power, or sitting still. No codes or any other explaination from the drivers seat that even gave away the fact that i was smoking, I am away from it now and will be for a few days. This weekend i am tearing into the thing full bore. Really need her up and running. Cant keep the company car or want to for that matter. Thanks so far for the info every one. I will let you all know what i find out. Thanks again for all the help...

05-16-2012, 05:31 PM
Has the truck lost power ???

05-16-2012, 05:33 PM
And pull the egr out shove the valve closed and tack weld it closed and see if it helps !!!!!!

05-16-2012, 05:38 PM
Cracked tip on the injector. Had an 03 yesterday doing the same thing.

05-16-2012, 08:05 PM
Mine did that a few years ago. It ended up being a seal in the turbo. It had an oily residue in the exaust. I don't think it is CCV because mine was rerouted when it happened to me. It took a couple of days to clear all the oil out of the exhaust after repairing it.

05-17-2012, 04:55 AM
The oil in the IC pipes is normal, as was previously stated, and wont do anything for your problem. I would agree with checking the EGR valve, but if thats not it I would check the VGT actuator as well. But the cracked injector tip sounds like your best bet!

05-18-2012, 01:27 AM
Ok quick update, pops got me a turbo another stocker, but I am trying to find a God deal on a full set of injectors, our can a just replace them in ones and two's. Call me crazy but I would rather just replace all of them at once and be done with it. Any suggestions? And thanks to everyone for helping out and getting my baby back on the road...

05-18-2012, 02:28 AM
I have never changed injectors on a PS yet, but I can tell you from a Cummins stand point. If you have a cracked injector, washed out tip, and/or a tip that is not closing off properly it will cause exactly what you are describing. I am not disagreeing with the EGR problems others have listed as well. My first thought would be injectors though. As for changing them out one at a time? Well that is a call for your budget, my man. Me personally, If you are having trouble with one it might be suspect of more to come soon. But if you are going to pay someone or even do it yourself, while you are there it would be a good call IMO. An ounce of prevention is worth 1000's when you have to do that much work to get to the injectors in the first place. IF it your budget doesn't allow, then yes you can change one or as many as you deem. Good luck with it.

05-18-2012, 02:49 AM
Ive changed my injectors and while it isnt a huge pain, I wouldnt suggest ones and twos. Simply because unless you have AE or another good scan tool, you will be guessing which is the bad one. And like power junkie said if ones going that could mean others will go soon.

Extended Power
05-18-2012, 05:02 AM
Mine just torched the tip off of one injector...
I have never been embarrassed to drive my truck till that happened...smoked like it had a tire fire burning at the back of the truck.

AE software showed cylinders #5 and #7 had contribution faults...but #7 had no tip at all left...the pintle was actually sticking out of the bottom of the injector.

Hope you get er fixed up soon.

05-18-2012, 01:31 PM
Keep us posted and good luck.

06-19-2012, 11:36 AM
Did you get this figured out yet?

06-20-2012, 08:03 PM
no still have the truck sitting in the driveway just putting it back together and having a shop do it I have found a shop called dependable diesel off the 224 in akron that is reputable witht the 6.0 I wish i could have done it myself but i have NO TIME to do it and honestly i really want to be driving my rig and not on the bike anymore I MISS MY AC lol. but honestly i am tired of seeing it in the driveway and know i cant go camping later on on the weekends or something vary frustrating...

06-21-2012, 01:54 PM
Ok one more quick question everyone. I put the truck back together last night, buttoned everything up and after a few beers and starring at my beloved truck i grabbed the keys hopped in and cycled the key on for 20 seconds and off twice, (like i normally do if i have let it sit for awhile) then turned the key and she fired right up almost instantly. Color me shocked!!! I figured if i had injector issues this would not have been the case. Yes i am still getting black smoke under throttle and letting sit at idle i am getting a lighter colored haze. I am constantly checking my overflow bottle and have not noticed any fluid missing what so ever. I am taking it to a shop today just figured i would ask this last question is all. Thanks.

06-21-2012, 02:47 PM
Shouldnt have to cycle your glow plugs like that especially in this heat, I dont even activate mine and she fire right up.

Yes it will still start. I'm curious what the fix is going to be.

06-21-2012, 05:23 PM
Me to, I am going to pull the EGR valve tonight and see if that might be it before i take it to the shop just to see. The fellas there even said to run it with out the airfilter on it for a minute (Stationary of course) just to see if it clears it up at all i have no idea what all it is going to be but am anxious to have her back up and on the road again... As for the cycling it was just a habit the glow plug light didnt even come on the second time at all...

06-21-2012, 08:56 PM
Did they say what taking the air filter off is supposed to do? Not sure I follow that logic. Unless they think you have a bag on it.LOL

07-03-2012, 08:19 AM
Did you get it back yet or is the shop still poking it with a stick?

07-05-2012, 03:42 PM
The shop's diagnostic showed a bad injector on the #2 cylinder, with no other contributing codes. Truck is back at the house now, waiting on the parts to arrive. I hate looking at it on the trailer... :( soon very soon...

07-05-2012, 04:00 PM
Long road to get to the diagnosis, but it could be worse.

07-05-2012, 10:08 PM
But at least i have a starting point and the the light at the end of the tunnel is ON AND BURNING BRIGHTLY...

07-11-2012, 10:15 PM
Sounds lke ficm to me

08-10-2012, 03:37 PM
Saw your truck sitting at the recruiting center.....she all fixed up or were you avoiding the rain?

08-29-2012, 12:36 PM
She is good to go now, back in the shop for routine maintenance, and full fluid exchange. The guys up at mullinax worked really well with me to get it running properly finally. just in time for my drive out to cali mid september. thanks for all the info and help

08-29-2012, 01:01 PM
Good to hear. Was it injector(s)?

You'll probably want to dump those stacks after a road trip to the west coast.

08-29-2012, 11:04 PM
yeah the number 5 and 8 injectors were shot and i didnt straight pipe it i left the cat on sounds good and the dyna mat i put it keeps it fairly quite just a little bit more in cab noise not bad at all.

08-30-2012, 02:10 PM
Did you dyna-mat behind the rear seat?
Not sure how much you put in, but the floor(tripled it on pass side over exhaust pipe path) and the door panels both shound be done. Dynapad over the top on the floor also makes a big difference.

I put sound matting in the back of my rear seat and it made a big difference, was surprised how much sound was coming through the back of cab. Sound matting also in the front firewall below steering column helps with injector noise. Mine wound up much quieter than stock after straight piping it, cannot hear engine at speed anymore.

08-30-2012, 09:19 PM
Dyna mat was one of the first things i ever did to the truck. behind the rear seat and entire floor of the cab. Was a pain in the butt to pull the interior out but well worth it in the end also took some one inch steel and made spacers to lift my rear seat up to clear my subs and amp trays. Most cant even tell i am driving during a phone call. that and i'm not obnoxious to others when i feel like turning up the radio a bit. A little pricy and time consuming but well worth it in the end.

08-31-2012, 01:33 AM
I am 100% with you on the dyna-mat, thats funny how you had to raise your back seat. I did the same thing but with 1/8 thick fender washers, stacked up 5/8 tall to clear the box I built with four 8" subs.
My back seat has sound proofing foam and a peice of 3/8 rubber between seat cushion and the metal framework, covers entire seat.
I went as far as putting 1" self adhesive foam-rubber sound proofing inside the doors, it just cleared the windows.lol Then dynamatted the doors, really does quiet things down.
I did not do the roof and wonder if it would make a difference or not ?

I'm sure yours is the same sound when the door is shut, soild like a Cadillac :cool:

08-31-2012, 01:50 AM
maybe someone already suggested this....didnt read all the way through but i had a stock truck that i had trouble starting and all it wanted to do was smoke and run rough like it was loading up, finally got it running and at idle it just dumped smoke and even more when revving it up, turns out it was a bad FICM had all 7 codes for that. only had to do half of one so that saved a good bit of money and ofcourse the warranty didnt cover electronics, just hard parts

funny part was when i got it running finally after it ran for a little and got warm it ran and drove fine.

09-04-2012, 10:06 PM
I had the guys at ford do a full diagnostic on it FICM voltage was good and it had no codes what so ever for it I was there when they checked it the guy at mullinax loved the fact that i was so interested in what all they were doing and he liked the stacks on her. I watched the whole test and watched him pull up the codes from the test only thing was the injector and a sticky egr valve doing the delete her in the next month or so. Thing runs like a scallded dog. I have zero complaints about it right now over the weekend i put a ton of milage on it just to make sure it was good to go before i head to cali this month. The door sounds more like a tank when it shuts than a caddy though lol

05-17-2015, 04:49 AM
Hey I had same problem with my 03 6.0 Powerstroke after replacing my two injectors that were given codes of fuel balance contribution issues and a brand new swamps diesel ficm still didn't fix it after a week of trying to figure it out it turned out to be the fuel pump wonder driver side frame rail was so pissed after putting 1,500 bucks into it and turned out to be a simple 200 dollar fuel pump