Before we start, yes the Milage is correct. I work as a Mechanic in Afghanistan for the Military. These trucks are low milage but ran extremely hard. This truck is equiped with a 6.0L powerstroke. The truck when runs okay till its within opperating temp and then will start dumping white smoke. This smoke is the result of a fuel issue. Recently this truck has has 8 brand new injectors, glow plugs & harnesses, an injector harness(because back 2 FICM plugs were broken), a new FICM, and a Camshaft position sensor. Now for the weird part, I recieved a tip from sombody to unplug the engine oil tempature sensor to put the PCM into manufactuar default for determining fuel quanity, I reshearched on Mitchell to make sure this would actually work and it did. Unplugged the truck runs great never any smoke and zero driveability issues. The truck never sets a DTC untill you unplug the sensor and when unpluged it sets the expected Engine oil temperature signal high. Yet runs flawless in manufacturer default. I conducted all the voltage tests and and continuity tests at the sensor and the PCM, and then alos isolated the circuit and checked for any shorts to ground. I found nothing, the entire circuit works perfect exactly as it should. So I know it runs correct unplugged because it makes the PCM determine fuel quanity by manufactuar default, but what could cause the fuel problem in the first place without settign a single DTC or cylinder contribution/balance fault. My IDS program and Modis Scanner read the entire system workign properly.
I'm not eally a diesel guy but looking over tsb's there is one taht involves coking which military vehicles idle for long periods of time maybe look that over as it may lead you to beleiveit's a fuel problem but actually not enough air problem causing the smoke. And if the egr wasn't working properly but at times giving enough air when you unplug eh sensor it may be why it's doing that. I do know that this engine is awfully hard on turbos as well so maybe a broken grommet or air leak on hot side as there is a tsb for that as well may also be a cause. Like I said i'm not a diesel guy an djust lookng over these tsb's kind think it may lead you in the right direction. It's worth a try anyhow. Esppecially ifthis truck is used as a radio type truck which would idle for an extermemly long time.
February, 21, 2013 AT 3:31 PM
Truck Fixed, it slipped my mind that the ICP sensor on the 03 powerstroke in at the high pressure oil pump and not in the oil rail. Drained oil, it was not saturated with fuel or coolant but it was 5w30. I immediatly changed the oil twice and filter the last time with 15w40 and allowed proper pressure to the injectors. With the ICP sensor being at the pump it was reading as correct pressure the entire time but was losing pressure at the rail due to low viscosity not allowing the injectors to complete a full open cycle. The 2004-2007 Ford moved the ICP sensor to the valve cover directly threaded into the injector oil feed rail which would have been able to indicate the problem from the start.
February, 21, 2013 AT 6:09 PM
That was also ne of the things onone of the tsb's they changed to run the 15w30 oil during certain temps on all models with teh 6.0