2007 6.0 with a Cylinder 5 Contribution/Balance Fault code.

While driving to the repair shop this morning it was idling a little rough and had black smoke that turned white at idle/acceleration. The smoke seemed to dissipate slightly at higher speeds. A spark knock began about half way there and as when I was literally 1/4 mile from the shop, it began billowing black smoke, made a horribly loud bang (sounded as though my passenger rear tire blew) and immediately began billowing massive white smoke.

I have been told that injector #5 is stuck open and the tip is broken. They claim the tip cannot be located after looking with a scope. They put a used injector in to test if the issued was resolved...spark knock was gone, idle sounded normal but it was still smoking white. They now want to tear into my engine to try and locate the "missing" injector tip.
**Picture of the #5 injector attached - Any advice/comments would be greatly appreciated!

 

Only place it could have gone is threw one of the valves if that's the case you will probly need a new head usually white smoke is coolant in the combustion chamber guaranty it did some damage I had a 12 valve Cummins I worked on that the guy did a injector swap and dropped a screw down into the cylandar and don't remove the head to get to get it out and put it back together and drove it by the time I tore into it he needed a new piston and head from rattling around in there never did find the screw most likely went out the exhaust valve threw the turbo and out the tail pipe

 

About 3 months ago my truck had the same EXACT symptoms as it does right now. (Black/White smoke, spark knock, rough idle, etc) It was cylinder #1 injector stuck open - replaced the injector and installed EGR delete kit, truck ran great with no more issues. This time it's cylinder 5 injector stuck open AND injector tip is "broken and missing". Here's my question: Did the injector tip "break" after removal from my truck and now I'm being lied to by the mechanic/shop? OR Did the injector tip really break before it was removed from my truck? I find it pretty odd that my truck SUPPOSEDLY has a missing injector tip that "has caused more serious damage that cannot be seen until my engine is torn down". The mechanic saw NOTHING wrong with a scope...my truck is experiencing the same symptoms as it did the last time it had a bad injector WITHOUT a broken tip! I've already been told by a few people that the chances of a truck that is only 6 years old with 65,000 miles experiencing a broken tip on an injector is way beyond rare and I have a better chance of being struck by lightning! LOL

 

Ya the chances with that low if miles are slimmer than hell but I have encountered some weird stuff over the years of working on diesels its not impossible but it isn't likely either I have also herd horror stories about some shops pulling stuff just to get you to come back which is why I started working on diesels on my own and only work on select people I know in my experiqnces working on 12 valves I would usually do a leakdown and compression check to see if there is anything internal buggered up but I'm not as familer with the 6.0 as I am with the 12v I own one and have only worked on a dozen of them

 

That loud bang tells you that there is a problem, it is very possible the tip broke and with all that fuel in there it popped your head gasket, and it is also very likely the tip went right out the exhaust. If the tuck still is all stock then the tip is probably in the front side of the Cat. converter.

 

Had the same thing happen to me in 2009!! in injector #8 after replacing the injector and draining a QT. of fuel from the exhaust manifold and driving around for abit the white smoke slowed but had a gurgle sound from the intake side that LITTLE HARDED piece of the injector nicked a valve.It only had 52000 miles on it. So here the dilema do you pay for the search for the piece??? with the Labor Charges?? Or do a long block and a turbo because it could have nicked a vane on the way out!! I took the second choice !!! Now with 12000 miles on the long block and two more Injectors replaced under warranty !!! The heap is out of warranty and just sent a code for #3 !! Man i love my 6.0 But its payed for!! Oh its a 2004!! Roll the dice!1

 

UPDATE - Went back up to the shop that told me I had severe internal engine damage due to the "broken injector tip"...I told them to put the parts in a bag and I would have it towed elsewhere. They insisted on putting it back together, after simply just replacing the #5 injector, and miraculously my truck runs perfect! I even stopped by another diesel shop on the way home and had all injectors/compression tested and everything tested perfect! Imagine that! After all the stress and concern, I did learn 2 things...1) I will NEVER take my truck back to that shop that diagnosed the "Broken injector tip"...Their nothing but a bunch of liars! (To say the least) 2) I found a fantastic diesel performance shop that I will be using from now on!

 

Good to here ya I've herd some horror stories if ships doing things like that

 

Im really glad it worked out!! A couple of questions did they find the broken piece?? And were you running a programer when the tip broke?? I was and they told me the reason why it broke was that it overheated!! Just trying to compare Notes.