OT: 99 PowerStroke issues.

Replacing injector Orings alone will not cure your problem. ..... BUT if you do coppers you will have to put new orings on anyway.

Good luck!

One thing to look for with bad o-rings on the early models are tiny bits of black debris in the fuel filter housing. As the o-rings disintegrate they are carried back in the fuel and end up in the housing. They don't look much like rubber or nitrile by the time they get there. I believe o-ring failure in a later model may not show up as black debris. I did this job once, and i believe the new viton ring in the Ford kit was pink and the other rings were orange and black and it came with new copper seals too. They come off with a very fine tip flat blade screw driver and careful work. Anyway, there was grey and blue smoke and a skip but no coolant loss with bad o-rings.

When you do modify with a chip, exhaust temps rise as your injecting more fuel and your risking valve damage from the extra heat. The later models have a much better flowing down pipe and exhaust than the earlier models for a mild "chip". All the chips i have looked at recommend improving air intake and exhaust flow to reduce the higher EGT's if you go past mild. Some guys install a pyrometer to watch their egt's with a chip. I ran a mild reprograming with the air and exhaust mods for more grunt towing. You guys with the newer trucks already have more power with the factory intercooler. I think i got about 40 horses, and basically was just catching up to the 98 up HP. The Super chips tuner reprograms the computer for more power and has 3 settings to choose from, and it will read the computer's trouble codes. A bonus for anyone considering a power increase and wanting a code reader.

Like any machine if your hard on it, it won't last. Those guys with the propane injection kits are blowing their motors apart, from what i read. Good luck.

Be careful about reading too much into a quart low reading on the degass bottle as my 02 PSD will hide a quart at times then show normal at other times. Where it hides the coolant is anyones guess but has become less as I get more miles on.

Have a oil analysis done. That will tell you how bad of a leak. Then you can tell from that about how many injectors are leaking. If no over heating problems then it doubtful it's headgasket related.

Since you have blue/gray smoke then you will also find the lower injector "O" leaking a small amount of oil.

Pay attention to the torque specs of the injector bolts. You can buy a Ford repair CD for about $25 and well worth the cost.

I also will get black/gray smoke after running mine at 1600rpm or lower for extended periods. I take it out on the InterState once every 3mths and run it at 2800rpm for a couple minutes. That will clear the problem for another 3mths.

I also reset the puter (disconnect both battery's over night, NO removing #15 fuse is not the same) once every two months. That helps keep my fuel mileage up and the engine running at it's best.

This is on a stock engine. If chipped all bets are off. The guys two years ago that were saying there's no problem with running "mild" chips are now having alot of mechanical engine problems!

T_Bone

mud

At the current stock fueling programs, Ford has a pretty good system going. One guy that has a 99' roll back tow truck had 995k on last year on a stock engine and exhaust and still running strong.

I feel it's how you use your eqipment. You drive them hard and put'm away wet then your not going to get much more than 200k miles out of one even with extensive mods.

Drive them at maximum torque RPM, 1600rpm, and allow for a 5min turbo cool down after pulling at maximum GCWR on a grade, then you won't have a problem. I also get 14.1mpg average using this method. Takes 1/2hr longer to travel per 250 miles using this method and is well worth the cost savings.

What I do is back off to 45mph on a flat road 2miles before my fuel stop, then another 2min to the fuel pump, you should be pretty cool for a engine shut down when at the pump.

The same could be applied to using a higher rpm but just allow a couple extra miles.

T_Bone

Link

They have provided me with some really good help in the past.

KEG

Just some thoughts.

Is the color at the exhaust long after warm up? If not, it could be just a darned glow plug is all that is dealin' you fits.

Those injectors are engine-oil-pressure fired. I've seen a lot of 'em cured with just a simple matter of changing the engine oil.

Believe it or not, I've seen many with air filters so plugged up that they were to the point of misfiring.

Since you are getting a blue/grey color, I'd run a bottle of injector cleaner thur it; might just clean 'er right up.

Yes, they had problems with the injector o-rings as you mentioned.

Next on the list is the injectors themselves; replaced quite a few of 'em.

They had problems with the galley plugs leaking oil both front and rear; however, this isn't your complaint.

Head gaskets just weren't much of an issue in the '99 models.

If all else fails, the beauty of that system is that you can run 'er by your local Ford garage, they can plug in the scanner and tell you exactly which cylinder is misfiring and will be able to give you a very educated guess as to what is going on with that truck.

My gut tells me that your engine misfire and the hot antifreeze smell are not related.

Hope you get 'er goin'

Allan

When the engine is shut down, a period of time exists when cooling system pressure is greater the that in the combustion chamber. Coolant leaks in and removes the oil from the rings/walls. That's the blue smoke. When you start the engine, the coolant is pumped out the exhaust, that's the white/gray smoke, the smell you notice, and the source of the coolant loss.

If you check the oil, you may find coolant in it as well.

A mechanic can run a cooling system pressure test and a cylinder leakdown test to confirm.