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6.0 #7 Cylinder Contribution

11K views 14 replies 4 participants last post by  jamiesaun  
#1 ·
Hi

A little background, I bought an 04 F350 4x4 with a 6 speed manual. I got the truck for cheap because someone forgot to set the ebrake and the truck rolled into their pond. The truck was pulled out in about 20 mins then sent to the shop to have all fluids changed. After the mechanic changed the fluids and started it the truck was puking white smoke. The mechanic called the people I bought it from and at that point is when they chose to sell it. It was the oldest truck in their fleet.

So when i bough it, it was blowing white smoke. I bought it knowing I was going to pull the heads and replace a lot of stuff anyways so it was a none issue for me. When I got back to my shop I went ahead and connected my Autel Maxicom MK808 to check the codes and see anything else there might be worth seeing. There were a couple codes for glow plugs and a code for cylinder 7 contribution.

Jump ahead to current, I have replaced the heads with remanufactured heads from American Cylinder Head in Oakland, CA (both were cracked). Installed new head gaskets, ARP studs, new OEM injectors, new glow plugs, new dummy and stand pipes, new oil cooler, upgraded EGR cooler, upgraded up pipes, 4" down pipe and exaust, blue spring mod, upgraded water pump, SCT BDX Tuner, Powermaxx turbo, and South Bend Dual friction clutch.

It's all back together and still blows white smoke and I am still getting the same cylinder 7 contribution test failure. The motor has 210,000 miles. The cylinders all looked good though I didn't do a compression test (which I should have). During tear down and cleaning I did not run across any needle bearings like that could be found in lifter.

Also I should note, the truck seems to have a replacement motor. The block has 18mm holes and has the early aluminum body HPOP. The heads on the other hand have 20mm holes and the IPC is located on the passenger valve cover and not connected to the HPOP housing like normally seen with the early model 6.0. Also should be notes the ICP used is from the later models with the brown connector and not the black connecter like from the earlier models.

So question is, any suggestions on what could be causing the #7 contribution failure?
 
#3 ·
Right now I'm just wondering how you got heads with a 20mm dowel onto an 18mm hole block. lol I've never checked, but do they make an 18 to 20 adapter? And it sounds like you have a 2004.5 model. The 2003 MY engine was used into the beginning of the '04 run (those were considered 2004.25) and then upgraded with the newer heads which have wavy oil lines and the ICP in the head. I've got one, but mine is an Excursion, so we got all the leftovers from the truck line which makes getting parts fun because you might have a number of combinations of model years. lol Sorry, I digress...

I guess my first question is what does the smoke smell like? That would be my first concern over the #7 contribution. If it's fuel, then it might make sense to have the #7 failure code if it were leaking fuel into the cylinder at all times. If it's coolant, I'd look at all the usual suspects and see what you can....might require a cooling system pressure test to see if you have a bad EGR cooler or something like that. As far as the injector goes, if you had the code before and after, my gut tells me it's something that you did NOT change. I'd begin by looking at the FICM voltage. If it's above 45 at all times then I would next inspect the injector wiring harness for shorts or opens. And don't forget to inspect the pins. I've bent pins on the FICM before without even realizing it. Damn things are so delicate compared to how tough these trucks are! lol

Anyway, those are just my initial thoughts. I'm sure someone smarter will come in and have a few other suggestions.
 
#5 ·
Well there ya go! lol I figured they must since they had different sizes between pre and post '04...at least I think that's the year.
 
#6 ·
Sorry on the slow reply I got sent out of town on a project.

Based off my research and what i have seen my motor seems to be a frankenstein. Its an early 04 with 18mm block and 20mm dowel heads. It has the early model aluminum body hpop (upgrade to a diesel site billet unit). Wavy high pressure oil rails with the ICP on the passenger side and not on the HPOP housing (hpop housing was also upgraded). Later model EBP sensor also.

Some updates since the original post. I did a pressure check on the high pressure oil system. There was a major leak which I assumed was the hpop since I hadn't replaced it when I did all the other work so I ordered a billet one from dieselsite (truck has the early aluminum body hpop). Turns out it wasnt the pump itself but rather the main oring (see attached image). Got it all back together including an updated HPOP housing and crank and cam sensor. Started it up and......truck ran like dog####. Long story short, I replaced multiple pig tails and replace all sensors with Motorcraft vs well, not Motorcraft. Truck finally started right way, runs really smooth, at least compared to what it had been. A lot more power, a lot better throttle response, finally had a smile on my face.

One issue, still white smoke that smells like fuel and getting the cylinder 7 contribution error still. Injector is Motorcraft which is a warranty replacement for the new Motorcrafts I had installed when I did the head gaskets, studs, etc a few weeks ago.

During all the troubleshooting I haven't been replacing the o-rings every time, i have always checked then for damage and replaced if I saw anything but otherwise I reused them. As it stands right now I have the valve cover off and injector pulled. I am planning to replace all the seals in hopes that maybe its just the fact I have pulled the oil rail and #7 injector a few times and not replaced the seals.

I performed a compression test when I first got the engine back together and all cylinders seemed to be within spec but I plan to test it again when get it back together tomorrow.

If it still smokes after I get it back together I feel like I am out of options and may just need to bite the bullet and pop the cab off again check out the bottom end? Sound right or am I missing something?
 

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#7 ·
Oh also, when idling the truck smokes something fierce but if I get on it the exhaust seems to clear up going down the road. When I come to a stop the smoke is pretty light but the longer I sit there the more it smoke.

If I disconnect the injector wiring on cylinder 7 the smoke goes away and the engine doesn't seem to noticeably run different.

Is it possible the computer learned the cylinder wasn't contributing for a long time so it adjusted to run without it or something and needs to be trained/taught?