Chart 9

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2004 Ford RV Cutaway, 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, and 2004 Ford Excursion. However, it is still accessible from the selected car via links, so may be relevant.

Exhaust System Concerns: Visible Smoke (No Oil Consumption)

SYSTEM/COMPONENT	REFERENCE (PINPOINT TEST - 6.0L DIESEL unless noted)
Preliminary Checks	PERFORM preliminary checks. REFER to Performance Diagnostic Procedures 1-4 in DIAGNOSTIC SUBROUTINES - 6.0L DIESEL . VERIFY any concerns.
Atmospheric Pressure Rationality Check	GO to DIAGNOSTIC METHODS - 6.0L DIESEL Parameter Identification (PID). With KOEO, SELECT Parameter Identification (PID). SELECT PIDs: EP, MAP and BARO. If any PID values/readings deviate from atmospheric pressure in your locale by more than 10 kPa (1.5 psi), GO to the appropriate pinpoint test for the sensor with the largest difference.
Check Color Of Exhaust Smoke	NOTE: Some white tailpipe exhaust smoke is a normal condition at start-up with temperatures below 10°C (50°F) or with an extended idle in a cool climate. START engine. If exhaust smoke is white, GO to next step. If exhaust smoke is black, CHECK for charge air cooler restrictions.
Check White Tailpipe Exhaust Smoke	GO to DIAGNOSTIC SUBROUTINES - 6.0L DIESEL , Hard Start/No Start Diagnostic Procedure. PERFORM Glow Plug System Operation Check.
Check Charge Air Cooler for Restrictions	CHECK for any conditions that may restrict air flow through the charge air cooler. DISCONNECT ducts at CAC and CHECK for restrictions. CHECK inside of CAC for restrictions. If there are any restrictions, CLEAN as required. VERIFY repair.
Confirm Fuel Quality	If concern is present, DRAIN fuel tank. ADD known high quality diesel fuel to tank. If the amount of smoke is decreased, ADVISE operator of need for higher quality fuel.
Check For Out-of-Range Sensor	NOTE: Ensure the vehicle temperature is stabilized. SOAK the vehicle at ambient temperature for at least 8 hours. Verify no accessories are in use (engine block or oil heaters).
CHECK operation of: intake air temperature (IAT) sensor, manifold air temperature (MAT) sensor, engine oil temperature (EOT) sensor and engine coolant temperature (ECT) sensor. If the sensor temperature readings are not within 12 degrees, REFER to the applicable pinpoint test in PINPOINT TEST - 6.0L DIESEL .
Check For Coolant Leak	Refer to the appropriate ENGINE COOLING article.
Check Thermostat Operation	Refer to the appropriate ENGINE COOLING article.
Isolate Engine Cylinders Generating Smoke	NOTE: When the vehicle is assembled, gaskets are not installed between the cylinder head and the exhaust manifold. If the exhaust manifold is separated from the cylinder head, gaskets must be installed. REMOVE the exhaust manifold attaching bolts. PRY the manifolds away from the cylinder head. START engine. If a cylinder is generating excessive smoke, CHECK compression. If not, TEST glow plug(s).
Check Crankcase Pressure	Refer to DIAGNOSTIC SUBROUTINES - 6.0L DIESEL . PERFORM the Crankcase Pressure Test.
Test Glow Plug	REMOVE glow plug from smoking cylinder. GROUND body of glow plug and INSTALL jumper wire from B+ source to glow plug terminal. If glow plug tip does NOT become hot, INSTALL a new glow plug. VERIFY repair.
Switch Fuel Injectors	SWITCH injector(s) between a smoking and non-smoking cylinder(s). If smoke moves with injector(s), INSTALL new injector(s). VERIFY repair. If not, refer to the appropriate FUEL CHARGING & CONTROLS article.
Black Smoke	NOTE: Check for air in fuel. Test with clear line at pump inlet. Refer to the appropriate FUEL TANK & LINES article for removing fuel lines.
Check EGR Operation	GO to DIAGNOSTIC SUBROUTINES - 6.0L DIESEL , EGR Position Test.
Check Mass Air Flow Performance	GO to PINPOINT TEST J: MASS AIR FLOW (MAF) SENSOR .