Help, have a 03 6.0 with 130,000 miles. Truck smokes when idling/fast idle grey color, smells like fuel and stinks like fuel burns your eyes. No codes on the AE, power balance looks good on the AE as well. Runs and starts good. Turns over good but I suspect a possible leaking injector. Turbo has been replaced and was bad also, and it had a plugged converter that is removed now. Truck does not smoke blue like it did with the Turbo bad. EGR has a block off kit and the cooler is removed. Oil cooler replaced, ICP replaced, EBP replaced both sensor were bad. I did not see bubbles in the filter housing when testing. I put all new orings and copper seals on the injectors when I replaced HG and torqued then to spec. 4 of the injectors are ford remans. I pulled the manifolds and ran it to try to find a smoking cylinder, drivers side looks clear and not burning eyes bad, passenger side all the cylinders look similar with light smoke, but they do let out a spark now and then out the heads when running. Driver side has no sparks. Smoke burns your eyes very bad and you cant hardly breath like fuel.

So since I can confirm that it is the passenger side, what now. I cant really find a cylinder that smokes a whole lot worse than the others. Possibly the second one smokes more but its really hard to tell. I suspect fuel since it burns your eyes so bad. What could cause the whole bank to be smoking, over fueling. Do I have a leaky injector possibly. Do I pull the injectors and have them tested? Where do I go now. No other problems other than smoking bad and burning eyes? Can the dealer run a better power balance than the AE? I'm at a loss. Help!

Update, checked for bubbles again in the fuel filter housing and nothing. I pulled the 4 injectors in the bank that it smokes from and did not see anything alarming. I have talked to a ford diesel tech and a international tech and neither have an idea. The ford dealer did not want to waist my money trouble shooting it. I am going to look for some place that can bench test the 4 injectors I pulled out to rule them out. All four are recent ford reman injectors. I have new heads, oe gaskets, studs, egr delete kit, oil cooler replaced, turbo replaced, icp replaced, ebp sensor replaced. The degas bottle hold pressure for days. I get grey/white smoke that stinks like fuel bad and burns your eyes but starts and runs great, good power too. Smoking seems worse when its warm and at idle. So far I have stumped every one. What would make it smoke on one bank?

 

wow!
I would start to think over fueling.
Do you see any fuel in your motor oil?

 

Fresh oil change since I got it, so I could not see if there was fuel in the oil. I considered running it this way to check that but was worried about doing more damage.

 

I sent 4 of my injectors from the left bank into Huckstorf Diesel Pump & Injector Service, Inc in Franklin WI for testing yesterday. Testing costs $35 a piece. I am crossing my fingers they find a bad injector. These injectors are about 2 years old Ford OEM remans, but one does show signs of leaking past the copper seal on a tear down before this time. All were sealing good this time. Maybe its possible previous combustion leaking past the copper seal did injector damage to this injector or another in this bank. That being said all 4 were sealing good this tear down. Should know later today the test results.

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Back to the drawing board, all 4 injectors test really good, no problems... they are shipping them back. Only recommendation their tech had was to have the truck flashed with the newest update.

Question does the FICM have a circuit for each bank? Just wondering if it could be a bad board in the FICM causing the smoking and still start and run good. FICM does test good for power.

What else could possibly cause smoking? Worse when warm. Grey and stink like fuel burn your eyes? I have to be missing something? Anyone?

 

Its an injector, they can test these all they want but unless they test them at 190degrees it won't show the problem you are having. Had the same issue for years, kinda felt bad for folks when I had to go into baltimore city I would be puffin smoke at every light. When I did my headstuds a couple weeks ago I replaced the right bank of injectors, allready did the left before and it still smoked, so after replacing them with different ones it cleared it right up. the truck ran fine at speed before but it would chugg a little and smoke pretty good, sometimes I could tap the pedal and the idle would smooth out and stop smoking. In my case it was definately an injector. I had a fuel pump dieing on me and it hurt the injectors some but this problem was way before that happened.