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Exhaust Smoke

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  1. Preliminary Checks

    Perform TEST 1: VISUAL ENGINE/CHASSIS INSPECTION , TEST 2: SUFFICIENT CLEAN FUEL , TEST 3: CHECK ENGINE OIL LEVEL and TEST 4: INTAKE RESTRICTION under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - 7.3L DIESEL article. Repair any problems as necessary. If no problems are indicated, go to next step.

  2. Atmospheric Pressure Rationality Check

    Turn ignition on. Using scan tool, monitor EBP, MAP and BARO PIDs. PID values should not deviate from atmospheric pressure by more than 1.5 psi (10 kPa). If all PID values are within specification, go to next step. If any PID value is not within specification, perform appropriate system test for the sensor with the largest difference. If EBP PID value is not within specification, see TEST DE: EXHAUST BACKPRESSURE SENSOR under SYSTEM TESTS in SELF-DIAGNOSTICS - 7.3L DIESEL article. If MAP PID value is not within specification, see TEST DH: MANIFOLD ABSOLUTE PRESSURE SENSOR under SYSTEM TESTS in SELF-DIAGNOSTICS - 7.3L DIESEL article. If BARO PID value is not within specification, see TEST DG: BAROMETRIC PRESSURE SENSOR under SYSTEM TESTS in SELF-DIAGNOSTICS - 7.3L DIESEL article.
    3. NOTE: Some White tailpipe exhaust smoke is normal at start-up with temperatures less than 50°F (10°C) or if engine is allowed to idle for an extended period in a cool climate. This test is for visible exhaust smoke with no oil consumption.

  3. Check Color Of Exhaust Smoke
    Start engine and allow it to idle. If White exhaust smoke exists, go to next step. If Black smoke exists, check for charge air cooler restrictions. Repair as necessary.

  4. Check White Tailpipe Exhaust Smoke

    Perform TEST 10: GLOW PLUG SYSTEM OPERATION under HARD START/NO-START DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - 7.3L DIESEL article. If fault is indicated, repair as necessary. If no fault is indicated, go to next step (Excursion and F250-550) or go to step  6 (Econoline).

  5. Check Charge Air Cooler (CAC) For Restrictions

    Check for conditions that may restrict airflow through CAC. Disconnect ducts at CAC and check for restriction in ducts and inside of CAC. Repair as necessary. If no restrictions are present, go to next step.

  6. Confirm Fuel Quality

    Drain fuel tank and add known high quality diesel fuel to fuel tank. If amount of exhaust smoke decreases, advise vehicle operator on need for higher quality fuel. If amount of exhaust smoke does not decrease, go to next step.
    7. NOTE: MAT sensor applies to Excursion and F250-550 only and may also be referred to as Air Charge Temperature (ACT) sensor.

  7. Check For Out Of Range Sensor
    Connect scan tool to Data Link Connector (DLC). DO NOT start engine. Using scan tool, access Engine Oil Temperature (EOT) sensor, Intake Air Temperature (IAT) sensor and Manifold Air Temperature (MAT) sensor PIDs. Turn ignition on. If EOT, IAT and MAT sensor PIDs are within plus or minus 11°F (6°C) of each other, go to next step. If EOT, IAT and MAT sensor PIDs are not within plus or minus 11°F (6°C) of each other, verify wiring harness and connectors are okay. For an EOT sensor that is out of range, see TEST DB: ENGINE OIL TEMPERATURE SENSOR under SYSTEM TESTS in SELF-DIAGNOSTICS - 7.3L DIESEL article. For an IAT sensor that is out of range, see TEST DA: INTAKE AIR TEMPERATURE SENSOR under SYSTEM TESTS in SELF-DIAGNOSTICS - 7.3L DIESEL article. For a MAT sensor that is out of range, see TEST DI: MANIFOLD AIR TEMPERATURE SENSOR (EXCEPT ECONOLINE) under SYSTEM TESTS in SELF-DIAGNOSTICS - 7.3L DIESEL article.

  8. Check For Coolant Leak

    Check engine for internal coolant leak. Using a pressure tester, pressurize cooling system. Start engine and allow it to idle. Note pressure gauge reading. If pressure increases immediately, check cylinder head and block for cracks. If pressure does not increase immediately, use pressure tester and pump cooling system up to pressure specified on pressure cap. If pump gauge vibrates, compression or combustion gas leak into cooling system may exist. Determine cause of internal leak and repair as necessary. See appropriate article in ENGINES. If pump gauge does not vibrate and no internal coolant leak is detected, go to next step.

  9. Check Manifold Intake Air Heater (MIAH) Operation

    PCM will activate intake air heater during long idle periods under the following conditions.
    • Ambient Temperature Must Be Less Than 32°F (0°C)
    • Engine Oil Temperature Must Be Less Than 131°F (55°C)
    • Vehicle Power (VPWR) Must Be 11.8-15.0 Volts
    • Parking Brake Must Be Applied On M/T Models
    • Gearshift Lever Must Be In Park Or Neutral On A/T Models
    • Glow Plugs Must Be Off

    Allow engine to cool if necessary, then start engine. If MIAH operates correctly, go to next step. If MIAH does not operate correctly, go to TEST KL: MANIFOLD INTAKE AIR HEATER under SYSTEM TESTS in SELF-DIAGNOSTICS -7.3L DIESEL article.

  10. Check Engine Thermostat Operation

    Remove and inspect thermostat for corrosion and proper seating of valve. Replace thermostat as necessary. If no problem is indicated, suspend thermostat in a container filled with a 50/50 mixture of coolant and water. Place a thermometer in container. Do not allow thermostat or thermometer to touch bottom of container. Heat water until thermostat begins to open. Read temperature on thermometer. This is the initial opening temperature and should be 192°F (89°C). Continue heating water until thermostat is fully open and note reading. This is the full open temperature and should be 219°F (104°C). If either reading is not to specification, replace thermostat. If both readings are to specification, thermostat is okay. Reinstall thermostat and top off coolant. Go to next step.
    11. NOTE: No gaskets are used between cylinder head and exhaust manifold when engine is assembled at factory. Always install NEW exhaust manifold gaskets when original exhaust manifolds are being reinstalled.

  11. Isolate Engine Cylinders Generating Smoke
    Allow engine to cool. Remove bolts retaining exhaust manifold to cylinder head(s). Pry exhaust manifold away from cylinder head(s). Start engine and monitor smoke from exhaust ports in cylinder head. If an individual cylinder is generating excessive smoke, go to next step. If more than one cylinder is generating excessive smoke, go to step  14.

  12. Check Smoking Cylinder(s) Compression

    Perform cylinder compression test on cylinders that emit smoke. If compression reading is less than 350 psi (2413 kPa) and different from adjacent cylinders by 50 psi (345 kPa) or more, repair engine mechanical condition as necessary. See appropriate article in ENGINES. If compression reading is 350 psi (2413 kPa) or more and different from adjacent cylinders by less than 50 psi (345 kPa), go to next step.

  13. Check Crankcase Pressure

    Perform TEST 11: CRANKCASE PRESSURE TEST under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - 7.3L DIESEL article. If crankcase pressure reading is more than 3 in. H2O, see appropriate article in ENGINES to check engine mechanical condition. If crankcase pressure reading is 3 in. H2O or less, go to next step.

  14. Glow Plug Test

    Remove glow plug from smoking cylinder. See GLOW PLUGS under FUEL SYSTEMS in appropriate REMOVAL & INSTALLATION article. Install a jumper wire between ground and body of removed glow plug. Install another jumper wire between battery voltage and glow plug terminal. If glow plug tip becomes hot, go to next step. If glow plug tip does not become hot, replace glow plug and verify repair.

  15. Switch Fuel Injectors

    Remove jumper wires and reinstall glow plugs. Switch injector(s) between smoking and non-smoking cylinder(s). See FUEL INJECTORS under FUEL SYSTEMS in appropriate REMOVAL & INSTALLATION article. Start engine and monitor smoke from exhaust ports. If smoke from cylinder moved with injector(s), replace affected injector(s). If smoke did not move with injector(s), repair engine mechanical condition as necessary. See appropriate article in ENGINES.
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