6.0l rough idle, diesel in exhaust, blowing white smoke
 

This is probably going to turn into a novel, but ya'll need the entire gist of things to make an accurate call. The truck is a ford f250 6.0l daily driver with the occasional give it hell. This all started after installing cylinder heads(remans from odessa cylinder heads), new oil cooler, stand pipes, and dummy plugs. Mods are in signature and no check engine light or codes are being thrown.

I recently put new heads on my 6.0l because there was diesel in my coolant. It only happened while it had ran for some time and was seen in the degas tank. It was determined to be the injector cups, but instead of changing cups out I went ahead and put new (remanufactured) heads on it just to be sure. Naturally I put new head gaskets on it along with every other gasket, plus a new oil cooler just to get it out of the way. After reassembly it was smoking and had a rough idle, but I thought nothing of it since it was the frst time starting up and it had air and possibly a little water in the cylinders. But after 15 mins or so it didn't stop and had only worsened. It smelt of diesel instead of a sweet smell of coolant so fuel is my next thought and usually it's a bad FICM, broken nozzle, or injector going out that will cause excess fuel to be dumped into cylinder. So I check injectors and their fine then I move on to the FICM, where I end up replacing it and the problem still continues. Next (after reading and searching many websites with no help), I go and check injector tips/nozzles again and their fine so I replace the two "bad" injectors(#6, #8) problem solved, NOT! Still smokes horribly and with the exhaust manifold lose while running, diesel is dripping out of it and when you take it off you can see diesel residue in the exhaust ports. So my next thought, well one of my first thoughts but was ruled out, is the copper crush washer. By this time I have my reman injectors, from NewJerseyItem, so I pull the injectors again and replace all o-rings and install injectors. The problem still continues. All in all the injectors have been taken out 4 or more times and new o-rings were used every time. Then I noticed it, while taking the o-rings off I didn't give it much thought, but the white o-rings on the leaking cylinders didn't appear used at all. They were still round and most of the white coating was intact versus the other injectors that their lower o-ring was oval and could tell it had been sealing off. So you think their not lining up or seating, but 4 out of 4 times? I just cant see that happening and the ridge on the copper washer is smashed as though its seating against the cup properly. Is it bad cups or is there anyway the cups were improperly put in the first time? Thats my last guess I just can't think anymore I'm so frustrated with it.

Does anyone have any ideas or know the problem perhaps? If it matters when diesel first started showing up in my coolant, I was draining it and put green coolant in it not even thinking about it. But that's just so you know everything, I don't see it being related and was corrected not long after. It may be something simple and I'm overlooking I don't know and I'm open to anyones recommendations. I'm to the point where I just wanna drag it in the field and lite it on fire. So ya'll are my last hope before taking it to a shop and spending who knows how much. Any questions please ask. Thank you.

Wow man, tough luck.

Personally I wouldn't use any injectors but Ford injectors, some of those "rebuilds" are sketchy. I've heard of some places "rebuilding" by simply swapping on new o-rings and calling them good. Seriously. It sounds like injector issues to me still, though why they wouldn't seat properly would be beyond me. Have you tried calling Odessa and explaining it to them? To see if there is possibly an issue with the heads themselves? I have heard good things about Odessa.

No I haven't called them yet but I intend on doing it tomorrow and hopefully it's happened before and they say it's definately the head(well it would be nice anyway). I'm just glad you've heard good things about them because I really didnt know going into it. They were cheap and I wasn't sure if my heads were cracked(should've had them magnafluxd) but was in a hurry and because of the cups went ahead an used them and they were easy to deal with so I thought nothing about it. And when my heads arrived they looked legit. But I'll know more tomorrow on that situation. And maybe it's the injectors still, I think I'm gonna swap the "bad" injectors for ones I know are good just do some swaping around to see if it is in fact the injectors. Maybe I fu#ked up when I did the whole remanufactured buy.

And another reason I didn't think it was the injectors was they worked fine before I changed the heads. Now I don't know how easily they can be messed up but I just took them out and put them each in a plastic bag til it was reassembly time an took them out, cleaned them with a tooth brush sprayed them off and let them dry then put em back in with all new o-rings.

A single piece of small dirt would stop up one of these injectors in a heartbeat. They say anything you need to do on them should be done in a bath of clean fresh diesel. It wouldn't take much at all to mess one up.

Ok I'll definately be more careful than I have been with them and try giving them a bath in clean diesel. Maybe something will break loose.

Just out of curiosity, is it possible the old copper crush washer is still in there and you're putting another one on the injector and then essentially have two stacked up in there? That would still show it being crushed, but not allowing the injector to seat all the way?

Honestly to me, it sounds like crappy injectors though, tough to say. Did you try calling Odessa yet?

Sounds like you have enough time stuck in this truck to have swapped in a cummins! :w2:

A couple of injectors and a FICM? I'd love to see someone complete an engine swap in the time it takes me to swap those few pieces.

Ill check on the copper washer idea, it would make sense but i've accounted for all that I've taken off so I don't know. No word from odessa yet hopefully I can get an answer tomorrow. I'll definately post the response I get. My dad has an 06 Dodge QC dually and it has plenty of problems when it wants so you can't act like their perfect. And the powerstrokes just look a lot better in my opinion, plus they can have a lot of power without all the noise. But I can't say I don't enjoy the sound of a good cummins every now and then either.

I'll stick with the powerstroke for now. And I agree with Mdub707 on the swap time.

took me 2 months and now i have a nice simple motor :jump: lol but everybody different