excessive smoke on light accleration and cruising

[Cutting-Edge Diesel]

I have a customers truck here that has left me scratching my head. Here is the back story.

We did new heads and studs as well as installing KC stage 2 charger and 190/30s. Truck was low on power and lots of smoke and found it wasnt maintaing at WOT. Customer wanted to install RCD thumper 2 HPOP. Now it maintains perfectly. We had some problems with the injectors going out and ended up changing to new 190/75s.

Now to the problem. It will just haze black smoke out the exhaust at 65+ MPH at sustained speeds. Egts also are on the high side at 1000-1100. With the old injectors I was contributing this to the problems we were having with the injectors. I install the new reman 190s and we have the same problem. So now im trying to figure this out.

Started with tuning. Changed every tune I had and it still does it. Even on a low power tow tune. So not convinced its tuning.

Truck is also on 37s with stock gears. So thinking maybe its the tires causing it with extra load and stock gears I install stock tires and wheels. No change,

Next I changed the turbo with a stock one. It lowered the egts but it still smokes. So not convinced it was the charger.


Also changed the FICM, air filter, boost leak test, exhaust leak test etc.


Data logging shows my boost and injector PW at cruising are higher than Charley normally sees. Boost is 6-7 range and PW is at 1.2 at 65mph. his truck with a stage 2 is at 3-5psi and .9-1.0 PW and 800egt



Unfortunately this customer lives about 7 hours away from our shop and ive already had to go pick it up once because of the injector issues so I dont want to have to go back!

Anyone have experience with this combo or this issue?

 

[Cutting-Edge Diesel]

edit wrong video

 

[white59rt]

MIne was doing something similar a long time ago - I am light years from the parts on that truck as mine is all stock. It turned out the EBP tube was clogged and not sure if that caused the sensor to go kaput or not but it was bad as well.

In that same visit also found on the ford scan tool at the dealer, luckily a buddy works there, that the map sensor was bad (mine is an earlier 05 I guess with the MAP).

Not sure which of the parts fixed the smoke but its been fine ever since those things were replaced.

 

[Cutting-Edge Diesel]

EBP reads normal. but not a bad idea to check the tube have had lots of problems with VGT turbos with EBP issues.

 

[Cutting-Edge Diesel]

https://youtu.be/U_cZYDXHiCU

 

[TyCorr]

Compression good?

The egts hot? We had a truck doing similar stuff and the turbo was leaking oil under boost and filling the intercooler and pipes with oil.

There was another 6l with stock injectors and a powermax that was hitting 1200 degrees just getting to 60 mph. He was seeing 1500 degrees to maintain highway speeds pulling his 8klb motocross trailer. Ill ask and see what they figured out on that one.

 

[Cutting-Edge Diesel]

Have not checked compression yet its been in my mind.


Egts are 1100 +- range maintaining 65.

No excessive oil in the IC pipes but ive wondered the condition of the intercooler on the inside.

 

[Cutting-Edge Diesel]

compression test 355psi, crank is nice and smooth.

 

[powerstrokelyfe]

Just throwing an idea out here, may be wrong. With the thumper 2, does that pump produce excessive oil, matched with only a 190cc injector ?

 

[Cutting-Edge Diesel]

no it shouldn't. the ipr will compensate and demand less. We had the issue before we swapped the pump as well.

 

[TyCorr]

Is your fuel pressure rock solid?

That boostleak test worked out ok?

Either you got a leak on the drive side and its not using that exhaust gas or the boost isnt making it to the motor. Thats either a leak, a bad charger, or an oil soaked/dirty charger.

Also throwing it out there but Ive had a "hot truck" before inly to find out my new autometer gauges pyro wasnt working right. :fustrate::cursing:

 

[Cutting-Edge Diesel]

fuel pressure is solid. Fuel lab fuel pump and regulated return.

no boost leaks or exhaust leaks. Checked both of those multiple times.

Charger has been swapped out with a stock one and still had the issue.

 

[Strokersace]

A rag left in the intake or something blocking airflow?

Honestly just throwing chit at the wall here.

 

[Cutting-Edge Diesel]

had the intake off whenever we would have worked on that last so no rag was stuffed in there. Thing makes great power and full boost at WOT.

loaded up stock tune and it smokes on take off and at 65 and might be worse.

Going to swap injectors again in the am.

 

[cRaZy8]

Leaky/cracked injector cup(s) leaking fuel into the cylinder(s)?

Bent intake/exhaust valve not opening all the way?

 

[6.0 Tech]

Still have the egr? What is icp voltage koeo? Does it roll smooth? Maybe brakes dragging or something? Maybe an ac compressor starting to lock up, or a dragging alternator?

 

[Cutting-Edge Diesel]

Leaky/cracked injector cup(s) leaking fuel into the cylinder(s)?

Bent intake/exhaust valve not opening all the way?

Ive thought about a leaking cup but when ive had that problem it normally smoked at idle and it was white smoke.


heads are new and truck cranks smooth and has a perfect balance test so I dont think its a valve train problem other than maybe a trashed cam.

 

[Cutting-Edge Diesel]

Still have the egr? What is icp voltage koeo? Does it roll smooth? Maybe brakes dragging or something? Maybe an ac compressor starting to lock up, or a dragging alternator?

egr ****** but still has the valve intact. icp voltage is normal.

I plan to look into anything dragging on the truck today.

 

[heavydoc]

Subscibed, Mine is doing kinda the same thing. I can hear a little tick at light throttle sounds like it could be a manifold exhaust leak but don't see any soot. Gonna install some gaskets next to see if it goes away.

 

[Cutting-Edge Diesel]

well found this yesterday while checking compression. put a new plug in there and didnt see a change so I moved on. this morning I was going to pull that plug again to see if it sealed up and its stuck in the head. So might be something there.