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Sep 7, 2009 | 08:24 AM

#31

collinsone

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Joined: Aug 2009

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i have not removed the header the fuel is coming out the gasket area before this i had alot of black smoke no fuel leak and no loss in power til end of trip 60 miles last 7 were loss in power a knock pass side a spark or two out tail pipe and muffled farts got it home cleaned egr valve started up thats when i noticed the fuel coming out no codes thrown temps were all normal this is all stock no extra guages 2003 6.0 4x4 whats the worst or is there hope only have 80,000 mi it has had the reflash cold start thing done already at 50,000

Sep 7, 2009 | 09:27 AM

#32

npccpartsman

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Joined: Dec 2003

Posts: 15,369

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From: Stuttgart, Ar

I'm puzzled about where the fuel could be coming from. Sounds like it's coming from the fuel filter housing and blowing/running down on the front of the head. I'm more concerned about the passenger side knock and sparks from the tail pipe along with black/grey smoke. How was the EGR valve? Almost sounds like turbo????? I'm really puzzled here.

Sep 7, 2009 | 09:42 AM

#33

matty169

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Joined: Dec 2005

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This is not going to end good I dont think.....

If you truly have fuel coming from a cylinder, you more than likely lost a injector nozzle, or atleast have an injector stuck open. Check your turbo to see if the impeller is still alive, and if you have a borescope, pull a glow plug and look at the piston, and the injector nozzle. I dont see this ending well, but good luck.

The turbo impeller you have to check is the hot side, pull the exhaust.

Last edited by matty169; Sep 7, 2009 at 09:43 AM. Reason: info

Sep 7, 2009 | 09:46 AM

#34

matty169

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Joined: Dec 2005

Posts: 604

Likes: 3

Try this.....

Take the oil fill cap off while running or cranking. If you melted a piston, which is what I think happened, you are going to have considerable blow by.

Dec 11, 2009 | 06:35 PM

#35

D8chumley

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Joined: Aug 2006

Posts: 4,929

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From: Oaks,PA

Mark- just an fyi, my bill from Ford today shows part # 4C3Z-9E527-BRM for injectors, your post shows -AA did they change part #s or did I get different injectors?

Dec 11, 2009 | 06:55 PM

#36

cartmanea

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Joined: Jun 2007

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From: Corvallis, OR

RM on yours is remanufactured, I think -AA are new.

Dec 11, 2009 | 07:09 PM

#37

cheezit

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Joined: Oct 2009

Posts: 12,123

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From: N. Fort Worth, tx

part numbers with rm are reman. the aa, ba etc are more revision numbers.
3c3z is o3-04.25 my
4c3z is 04.25 and up.

and sounds like you melted a piston and a turbo charger. once again remove oil fill cap and crank see if it stars puffing smoke like a fright train. also remove oil filter cap and check for melted stand pipe.

Dec 11, 2009 | 07:23 PM

#38

D8chumley

Resident smarta$$

Joined: Aug 2006

Posts: 4,929

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From: Oaks,PA

Quote:

and sounds like you melted a piston and a turbo charger. once again remove oil fill cap and crank see if it stars puffing smoke like a fright train. also remove oil filter cap and check for melted stand pipe.

Sweet Jesus, my heart just dropped when I read that for a split second I thought you were talking to me! Whew! So if they charge $369.10 for one rebuilt inj, how much do they charge for a new one? Sorry for the bad info. Good catch!

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Dec 11, 2009 | 08:55 PM

#39

cheezit

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Joined: Oct 2009

Posts: 12,123

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From: N. Fort Worth, tx

you cant buy new injectors all are reman so far as I know.
for example 4C3Z-9E527-BRM would replace 4c3z-9e572-aarm as well as 4c3z-9e527-aa or ab

I just did a set of 8 for a fleet at $285.00 ea. and 650 in labor + a fuel tank $485 and 340 in labor for a delaminated tank = $3755. and thats a deal

I just dont know how people afford to drive them sometimes.

Dec 11, 2009 | 10:23 PM

#40

cartmanea

Lead Driver

Joined: Jun 2007

Posts: 6,757

Likes: 5

From: Corvallis, OR

Quote:

Originally Posted by cheezit

As a college student, I certainly couldn't afford it if I couldn't do my own labor. Also, there are other sources for parts other than Ford, usually at a 30-50% savings. I've seen remanufactured injectors for around $150 each.

Dec 12, 2009 | 08:42 AM

#41

william_04_x

Lead Driver

Joined: Nov 2007

Posts: 5,139

Likes: 209

Quote:

Originally Posted by cheezit

And i'm sure all of that could have been avoided with a fuel pressure gauge..

Dec 12, 2009 | 04:51 PM

#42

cheezit

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Joined: Oct 2009

Posts: 12,123

Likes: 35

From: N. Fort Worth, tx

Quote:

Originally Posted by william_04_x

And i'm sure all of that could have been avoided with a fuel pressure gauge..

well most of it.. the rest is called not running bio in a steel tank. it seems to eat the spray in lining. I however run all the free bio I can (i have a plastic tank) because we get to keep the pump out fuel when we do the job.

Feb 19, 2010 | 11:48 AM

#43

AndeyHall

Posting Guru

Joined: Jun 2009

Posts: 1,373

Likes: 0

From: Anderson, SC

Quote:

Originally Posted by bismic

Here are four videos I found interesting:
Driveability concerns that lasts 3-5 minutes on cold start-up):
<TABLE style="WIDTH: 584pt; BORDER-COLLAPSE: collapse" cellSpacing=0 cellPadding=0 width=779 border=0 x:str><COLGROUP><COL style="WIDTH: 584pt; mso-width-source: userset; mso-width-alt: 28489" width=779><TBODY><TR style="HEIGHT: 25.5pt" height=34><TD class=xl24 style="BORDER-RIGHT: #d4d0c8; BORDER-TOP: #d4d0c8; BORDER-LEFT: #d4d0c8; WIDTH: 584pt; BORDER-BOTTOM: #d4d0c8; HEIGHT: 25.5pt; BACKGROUND-COLOR: transparent" width=779 height=34>mms://multimedia.ford.com/seopts/Tech25_250k.wmv

<TABLE style="WIDTH: 327pt; BORDER-COLLAPSE: collapse" cellSpacing=0 cellPadding=0 width=436 border=0 x:str><COLGROUP><COL style="WIDTH: 327pt; mso-width-source: userset; mso-width-alt: 15945" width=436><TBODY><TR style="HEIGHT: 47.25pt" height=63><TD class=xl24 style="BORDER-RIGHT: #d4d0c8; BORDER-TOP: #d4d0c8; BORDER-LEFT: #d4d0c8; WIDTH: 327pt; BORDER-BOTTOM: #d4d0c8; HEIGHT: 47.25pt; BACKGROUND-COLOR: transparent" width=436 height=63>Injector Diagnosis
mms://multimedia.ford.com/seopts/Tech12_250k.wmv

6.0L Fuel & High Pressure Oil Sub-System Diagnostics

</TD></TR></TBODY></TABLE>
<TABLE style="WIDTH: 327pt; BORDER-COLLAPSE: collapse" cellSpacing=0 cellPadding=0 width=436 border=0 x:str><COLGROUP><COL style="WIDTH: 327pt; mso-width-source: userset; mso-width-alt: 15945" width=436><TBODY><TR style="HEIGHT: 12.75pt" height=17><TD class=xl24 style="BORDER-RIGHT: #d4d0c8; BORDER-TOP: #d4d0c8; BORDER-LEFT: #d4d0c8; WIDTH: 327pt; BORDER-BOTTOM: #d4d0c8; HEIGHT: 12.75pt; BACKGROUND-COLOR: transparent" width=436 height=17 x:str="mms://multimedia.ford.com/fordstar/61914.wmv ">mms://multimedia.ford.com/fordstar/61914.wmv </TD></TR></TBODY></TABLE>

<TABLE style="WIDTH: 327pt; BORDER-COLLAPSE: collapse" cellSpacing=0 cellPadding=0 width=436 border=0 x:str><COLGROUP><COL style="WIDTH: 327pt; mso-width-source: userset; mso-width-alt: 15945" width=436><TBODY><TR style="HEIGHT: 12.75pt" height=17><TD class=xl24 style="BORDER-RIGHT: #d4d0c8; BORDER-TOP: #d4d0c8; BORDER-LEFT: #d4d0c8; WIDTH: 327pt; BORDER-BOTTOM: #d4d0c8; HEIGHT: 12.75pt; BACKGROUND-COLOR: transparent" width=436 height=17>Miscellaneous: Stiction, Injector Buzz test, Diagnostics, etc
mms://multimedia.ford.com/seopts/Tech25_250k.wmv

</TD></TR></TBODY></TABLE>

Also - link to "Injector Balloon test"
https://www.ford-trucks.com/forums/799530-how-to-test-ipr.html

</TD></TR></TBODY></TABLE>

HOLY *****
I tried watching that first video and between their horrible tv skills and monotone voices, I was knocked out within the first 2 minutes. Probably some good info in there, I just couldn't put myself through it to find out.

Mar 28, 2010 | 12:51 AM

#44

powerstroker100

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Joined: Mar 2010

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From: Upstate NY

subscribed

Mar 28, 2010 | 09:32 AM

#45

1_BIGMOFO

Elder User

Joined: Sep 2007

Posts: 589

Likes: 0

From: N.Y.

GREAT WRITE UP!!!! Thanks a ton man!!!

If I have an 04 im sure to have the black tops right??

Early Injectors: (White Top)
Ford Part Number: 3C3Z-9E527-AE
Fits 2002.5 - 2003 Ford Powerstroke 6.0L
International Part Numbers: 1843089C91, 1845879C91, 1843481C94, 1843481C95
Fits 2003 - 2004 International VT365 6.0L

Late Injectors: (Black Top)
Ford Part Number: 4C3Z-9E527-AA
Fits 2004 - 2006 Ford Powerstroke 6.0L
International Part Numbers: 1844751C2, 1846692C92
Fits 2004 - 2006 International VT365 6.0L and VT275 4.5L

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