Ford 6.0L Power Stroke Diesel :: 2004 Excursion Running Rough / Smoke Coming Out And Stalling
Feb 11, 2016
I have a 2004 Excursion with a 6.0 Bought the truck already studded, EGR deleted, and a 54V FICM. When I bought the truck it had a hot stall, no restart problem. Found the high pressure oil leaks and resealed them by replacing the #3 injector and replacing the top injector seal in the #4 .Oil pressure reads very good now and I drove the truck for a couple weeks problem free.
Truck started smoking (white to gray) and felt like it had a miss. No misfire or contribution codes. Truck failed the bubble test and I narrowed the leak down to the passenger side by removing the banjo bolt
Banjo bolt at the front of the passenger head
Found the #3 injector loose...the copper washer
Copper washer had disintegrated/melted and appeared to be stuck to the side of the injector. Scraped off easily enough, cleaned up the injector and injector cup and reinstalled the injector with new O-rings and copper washer.
Put the truck back together and still smoked the same and still felt like it had a miss. Ran KOER test and found sometimes a contribution code for #2 and sometimes #6 .
Drove the truck to work and it didn't feel down on power...mostly just smoked and rough idle...but on the way home there was a lack of power and just as I pulled into my driveway the truck stalled...wouldn't restart. FICM voltage was good, high pressure oil read over 900, IPR was holding around 40%.
Pulled the secondary fuel cap
Secondary fuel cap to run another bubble test...there was no fuel in it...completely empty. Started to think that I had a fuel feed problem. Hooked up a fuel pressure gauge
Fuel pressure gauge and drove the truck again...pressure wasn't great (45 lbs) but never dropped below 42...not even when it stalled. Pulled the cap again...dry again...yet the truck read fuel pressure.
Research showed that I was possibly pressurizing the fuel system with combustion pressure and that was possibly displacing the fuel from the fuel system. This would explain the run for a few minutes, then stall and no restart for a few minutes...I'm assuming that the pressure would bleed off and the fuel pump would start over.
Still failing the bubble test and still pointing to the passenger side. I pulled and recleaned the injector and cup...new orings
oRings and copper washer. Bubble test again...fail.
Pulled glow plug from #3 , failed bubble test still.
Pulled glow plug from #1 , failed.
Pulled #5 , failed...pulled #7 ...failed.
With no glow plugs in the passenger head I am still bubbling up to the fuel filter housing. Pulled the banjo bolt from the front of the drivers side head...no more bubbles.
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Truck started running rough on way home the other day. First gave me P0404 code and would get black smoke along with whitish smoke coming from the tail pipe. I haven't been able to notice or track an amount of coolant loss yet.
Swapped EGR valve this morning and now noticed this once she kicked into high idle (still warming up). About to hook up the IDS, hoping I this is not head gasket .
[URL] .....
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When I first start my excursion in the morning, it starts fine, idles fine. If I don't let it sit for about 5mins plus i have this issue. I will start off and it has no power at all. I can barely get up to 20mph. It doesn't seem to want to change gears, I don't hear the turbo spool up. Then all of a sudden it will go to next gear, turbo spools up and it has power again. It is like I said a 6.0 power stroke, its a 2004 excursion with 214k miles.
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So,I am working on a 2003 F250 6.0 manual trans. all stock. 204,000 miles. I got it not running. Charged the batteries and pulled the 14 codes accumulated by the last people trying to work on it.There were cyl 1,2,5,6,7,8 contrib codes, P0403 and P0405 egr(the egr was unplugged when I got it), P0341 Cam pos., P0500 VSS, P0562 voltage low, P0683 glow plugs, P1378 fuel inj. ctrl., and a P1000. It is on it's second used car lot, no one can fix it and I don't know what they have done.
Cleared the codes, removed, cleaned, replaced the EGR, installed new batteries, and went over the wiring harnesses. I am down to the P1000, an occasional P0405, and random cyl 3, sometimes 2 contrib codes. If I warm it up and clear the codes, I don't get any contrib codes.
I hooked up the Scan Gauge and the ICP is 554-up cranking, starts without any long crank, runs at 644 at an idle, revs up and reads 2404 max. This is sitting in the garage.
The IPR was 14.8 to start off with, running mostly between 29.7 and 38. revving it up. The FMD is steady 48.0. I have run the buzz test both warm and cold- sounds good, no faults found. Have run the KOER and KOEO demand tests, no faults. There is no smoking. I have changed the fuel filters. I have not located an adapter to hook up my fuel pressure gauge.
As it is right now, it starts reasonably well (it's in the 20's here at night). It runs rough until the temp gauge gets to the top of the little thermometer symbol, then it runs better. The turbo sounds like it's operating as expected, nothing weird. Cold it has a rough idle and poor throttle response. Warm it idles well, with an intermittent light "shudder" .
The weirdest thing I find is the fuel pedal, when I rev it up warm, it won't come back to idle right away, takes 10-20 seconds. It also does this shifting. It does not rev up on it's own, and it will stick at any RPM. I did not find a value for TPS on my datastream on my scan tool (Auto Xray Tech scan 7000). When I let off the throttle the IPR and HPOP pressure drop. The truck was hardly driven for the last 7 years (6000 miles).
I have added some Archoil 9100, that smoothed out the warm operation even more, it drives perfectly down the road (300 miles the other day). I sent the FICM (the guys on the other forum insisted my problem sounds like the logic side of the FICM) to Ed, got it back, no change. I took a peek at the IPR, it is shiny and clean, the connector is tight and free of oil.
I removed and inspected the throttle pedal, it's seems clean and operational. It only has the cylinder contrib codes cold, and it is usually only one cylinder, that cylinder changes, first it was 8 a couple of times, then 3, then 2, now 7. Which injector could be bad and there is no smoke.
I guess the biggie here is to get the throttle to stop sticking. It runs better everyday, but the sticking could be dangerous. The rough running cold cold just be this engines normal. The light shudder at idle goes in 3-5 second increments- light shudder-smooth-light shudder-smooth...
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My truck has been having this issue pretty much since I have had it, but it seems to be getting worse, or so I think.
When the truck is cold, it does not want to move very well. Like it's missing, and it does this until it gets warmer. Also, I have puffs of blue smoke come out the tailpipe when this occurs with it cold.
Injectors? Injector o-rings? Stiction?
FICM volts are good at 46.5v-48v when cranking.
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2005 6.0 133000 miles... Truck has been stuttering and running rough for about 2 weeks, warms up and is somewhat better. Would stutter in the RPM range of 1600 to 2100 RPM, can push down on accelerator and power through it with no problems. Checked codes and got PO269 Contribution Cylinder 3. Changed all filters and oil change along with a bottle of hot shot secret in the oil. Truck is now blowing blackish grey smoke under throttle and when idling that smells like fuel. No coolant in oil, and no oil in coolant.is the injector shot, or injector sleeve bad?
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I just looked back and it has been since July 7th that my girl has been sitting in my shop. Well this past weekend I finally got her back together and started. It took a while to build pressure but she finally came to life..
While I am thrilled that she is running again i have low power before the boost kicks in and is idling rough with a blueish- white smoke coming out of the exhaust. Once i kick her a little she will get up and go but I've never had the smoke before.
I'm thinking maybe a bad injector???
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2004 f250 6.0, 173k miles. I just had the head studs done and a new head due to a crack in one head, I got it back 3 days ago and she was running great. I towed my landscape trailer yesterday full of mulch and only went about 5 miles with the load, after the job driving to another one I noticed it sounded like it was missing at idle with a small amount of white smoke. Drove it home let it sit overnight, started it up this morning and a cloud of white/ blue smoke and a horrible rough idle. Smoke does not stop.
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My 04 PS was blowin white smoke constantly while running. I just towed a uHaul from Connecticut to Virginia Beach and had some coolant issues on the drive down (I was out of coolant on 95 in PA, added coolant and it made the rest of the drive no problem). I got here to Virginia and it was low on coolant again. I added coolant to it, and now I have some other issues. I had what looked like oil comin out the stacks onto the bed, so I pulled the turbo thinking it was seals. But the turbo was just rebuilt prior to me buying it with a wicked wheel in it. It still had stock EGR and it has 202K on it.
Checked and found EGR valve was wet. Ordered an EGR delete kit, and just finished installing it. Now with everything put back together, the truck doesn't want to start. It cranks but doesn't fire. I pulled the codes from my tuner and I got: P0403, P0405, P0683, and P2623. I know P0403 and P0405 are related to EGR but the others I'm at a loss on. The EGR delete kit I bought included the blank to remove the valve but what do I do with the plug that used to plug into it? Any way forward to get the truck back up and runnin again? This is my daily driver and not lookin to break the bank to get it goin again but I really need her to be reliable.
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So I bought an 04 3 months ago everything seemed good all deltas were good had a small leak nothing serious. I had the egr deleted then i did the mistake of flooring it 1 morning at top end and the mech is telling me threw a valve. The truck was stumbling and running ruff with white smoke. looks like cycl. 7 took a hit and shows 10 psi of compression. The injector are in working order and so are the rockers. the bill is 3500 all in for new gaskets and oil cooler head work, arp studs and labor.
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2004 Excursion... 1st time into a 6.0 for me so I took my time. Truck has 192000miles.
PHP Ficm atlas 40, 58V Swamps
SCT Tuned via X4 (recently)(Extreme street at the time)
Synthetic 0w30 summer and 0w40 winter.
FORD filters ALWAYS, 5000mile intervals no pushing it
FORD fuel filters, BOTH regularly.
Studded, AFE Stage 2, Liberty EGR Delete.
42's, 4:88's with Detroit in rear
Highway driving and feel a stumble. Weird, then another, ok that wasn't a bump. Then steady rough idle and a heavy vibration when I lightly got back up to speed to get myself home.
Had new filters so started there. Just changed in the spring here and they were in pretty new condition but swapped them out anyway. Stripping the cap, 120 bucks and had to put a new one on.
Start truck and still rough idle, test drive and still a bad vibration.
SO, I read and search. Scanning with Ford or AE are my number one priorities and they were done along with Fuel pressure check.
Scan revieled Inj 6 out, fuel pressure at 60 PSI. We pulled plugs off injectors with results except 6, confirming it's not working.
Ordered an injector and the Aliant Power rebuild kits to freshen up the other 7.
Disassembled all 7, NO stiction problems at all and all 7 spool valves were clean as a whistle. Bodies of injectors were good on 6 of them and had a screen in cyl 3 what was completely gone (the 3 screens around the body of the injector). Tip was also plugged but one hole. (used brake cleaner in tip and air to confirm 6 holes were clear) Used the body of the core on that injector but not the spool part. Replaced all O-Rings incl the seal inside the top where rail snaps into. Sanded spools (800grit 2-3 turns) and installed same way they came out. Stem pipes and dummies new as well.
Reassemble, carefully and fire truck. WOW....running abit rough but smoother. Ive read it takes abit to get air out of system and to expect longer cranks ect. Shut it down. INspect for leaks. Button up the ficm, and few other things. Re-fire truck with abit longer of a crank. Fires and running smooth. HERE's where it starts acting up again. I can feel a small stumble....then another....then full time again. Exact same as before. Pull 6 off and it's that injector again.
Here's the big mistake I made. Reinstalling injectors, I put the new one in #4 spot and number 4 in 6's spot. Not smart, I know.
Pulling inj plugs off around entire motor while running and def No 6.
Put things away, call buddy and he says possible FICM. or harness.
So i pull inj harness and OHM every single pin and map it. 100%, I go grab his "good" ficm and test with that. HOLY COW, FOUND IT. Started great... Then as she warmed up ICP at650ish, EOT ECT getting to 100-110F (only a 4-5* delta always monitor) is starts to vibrate and run rough again.
Read some more....OHM testing is one thing, actually load testing harness confirms if it's actually no good. Harness is 450 bucks plus our lovely 13% tax so I want to diligently cross this bridge. Grab a harness off a running 6.0 and test next day.
Fires up and runs smooth. Then, as temps come up it starts again. Walked away last night and when I fired up this morning. Started great and as she warmed up vibration was back. Along with a intermittent squeak from the turbo housing area.
Codes.... SCT X4 tuner is reading nothing DTC's and hasn't since day one so I "assumed" no codes until buddy scanned with AE and since it's last WiFi update wouldn't connect to computer and gives me error code 10007 when I try to tune. **Ended up fixing last night, went into another "Tune revision update" and now connects to my computer AND returned my truck to STOCK and resested truck. Still running rough.
So I plug my PHP FICM tuner and get codes:
P1102 "Unkknown" (reading here I had my AFE off and not plugged in)
P0113 Intake air HI input
P0284 Cyl 8 cont/bal Fault
P0603 Internal control Module KAM error
P0611 FICM Perf (58v swamps, I've read always throws this code and I've had that code since day 1)
P0676 Glow #6 fail
Lastly I'll add, no smoke out tail pipe at all during all testing minus the black puff when tune loaded.
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Ok, so I have a 2004 F250, with 6.0L. when driving at a steady speed (doesn't matter what speed), the engine will run rough when coming to an idle, and stay running rough until I shut it off and let it sit for a bit.
After I cycle the key a few times it will fire up and run fine, so I came to the conclusion that air is getting in the fuel system. I then took the filter cap off that is located in the engine bay and cycled the key, which produced a lot of bubbles, which I am assuming shouldn't happen.
I guess my question is, should I have air bubbles in the filter bowl, when cycling the ignition?
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Having trouble with 6.0 powerstoke white smoke out exhaust. We have installed egr delete and still have white smoke and water coming out of exhaust not as much as before. Took it back apart to see if we did anything wrong everything look ok. We did a compression test on all cylinders they check out ok.
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I have a buddy at work who has an 04 f350 6.0 that is running very rough. we put a scanner on it and disabled the injectors and 1,7,8 have no change. He checked the FICM voltage and is getting 48 volts on crank and run. He checked the wiring for anything loose or rubbed but nothing seems wrong.
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E99 Romps on start up and randomly dying. Bought this truck about 3 weeks ago. Previous owner mentioned he had issues with it getting hot and shutting off and not starting. Has new IPR, ICP and pigtail, I just put in a new fuel filter. Has 206k miles on it and is the 4R100.
The past two days after sitting all night I have been cycling the key twice and it hasn't done its romp. Typically when it does I can tap the pedal once and it goes away. This I could deal with but its started to die randomly while driving, never while cruising down the road. Its either just after starting it and rolling slowly or slowing down for a stop or to turn. When it dies, I can put it in neutral and it fires back up no problem. SES light usually comes on for about 10-15 seconds after but goes away.
Replaced the grey CPS that was in it with a dark grey one from RiffRaff Diesel. Got a Edge CTS2 to figure out the problem, the codes Im getting are P1280 and P1247.
The ICP pigtail they replaced they spliced on with butt connectors. I plan on pulling it to check for oil and make sure it does look new and redo the connections with solder then shrink wrap them.
I was told to check the IPR% under full throttle which I did and it never went higher than 36.7
The truck did start running rough around 45-50 mph and I did get a video of the ICP jumping around while cruising down the road.
Then I went through a drive through and the truck kind of hiccuped like it wanted to stall and the ICP went right to 725 PSI and idled up and stayed there until I started to leave.
Truck is pretty much stock, K&N air intake and muffler cut out and straight piped.
Here is a link to the videos I got :
e99 7.3 ICP fluctuation while driving - YouTube
e99 ICP steady at 725 PSI after acting like it wanted to stall. - YouTube
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I had been fighting some problems with injectors for several years. I didn't have time to dig into it. I knew what I needed to do, just needed to find time to do it. I honestly thought it was and injector and thought I would have to go to new sticks because I've had so many problems with the remans.
Well I finally had time last week. I pulled the passenger side valve cover and ohmed the injectors. It would be almost impossible to get the leads in the injector while installed the truck. I kept an old valve cover harness, so I cut a pig tail off of it and plugged it into the injectors so I could test. You can see the meter attached to the pigtail in the pic.
To my surprise all four were all right around 2.7 ohms. You need to set your meter so you are getting a reading w a decimal. If you set it to high it will only show a whole number and it is better to have a more accurate reading.
I then plugged the wiring harness back in and tested it from there. The #7 injector gave over 6 ohms. This told me that my wiring harness was bad. I went OE and replaced it. I had a problem w a Dormant valve cover gasket before so didn't want to go that route. After I replaced the gasket and harness all my readings were under 3 ohms. They were all lower than w the old harness.
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I have a 7.3 that's running rough. Started it the other day it ran alright but started blowing white smoke. Bought a oil and fuel additive i was going to run through it. Came a few days later, it stated up and was real loud and sounding like it was loping. It blew a good amount of white smoke, but it just smelt like real heavy diesel. Now i can only turn it over and it won't start.
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7.3 auto, starts and idles OKAY, drives fine if you have a light foot but trying to go faster than 50mph or more than 2000 rpm and the whole thing has an anxiety attack. Starts sputtering and popping, lots of grey smoke when it runs rough rough, let off the throttle and it MIGHT behave nicely again.
New lift pump, cleaned the pickup tube, fuel bowl fills nice and fast, just had my edge attitude juice tuner removed since it was causing similar issues that went away for the last 2 months, changed my IPR and CPS (had a mechanic test everything when the tuner was taken out, all injectors buzzed good, sensors good)
When this first happened after the initial problem with the tuner was resolved, it did throw the CEL, but I have since been able to get it to come back on, and my buddies OBD2 scanner wasn't even registering my truck when I hooked up... Dare I say PCM is to blame?
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05 6.0 deleted and studded. 170k fresh filters and oil, no CEL or codes.
This has happened 3x in months, so it intermittent. Truck will start fine cold, except for this last episode ....
Truck starts right up, idles correctly, speed bumps up if its cold enough to trigger the high idle. About mid way through its warm up, at approx 130-140 idle falls off, barely runs. Almost knocking. Black smoke if you give it throttle. Has no power when its doing this. Truck will not move and almost dies in gear. Give it til 185ish degrees then pooof! All good.
However 2 days ago it wouldn't start. Cranks but won't catch. Stumbles and dies. Finally got it to start after setting the charger on it. I killed it. But this time when it started it was straight into its rough idle, no power...until about 180. I switched it off, restarted it and it was totally fine
Ficm is 47-47.5. Every now and then I see a 46.5 for a split sec
Hpop is 700-800cold cranking.
Not sure what else to look at.
Moto craft filters.
Amsoil 5w-40
Archoil in the fuel and oil
Twc3 at every fill up.
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06' with 85,000 on it started smoking yesterday. When idling , and stopping at red light, and then sometimes it doesn't. Run it this afternoon for about 10 miles, let it warm up. Ran good and smooth didn't smoke when cranked then at the red light it started to put out a little white smoke. Drove back home, pulled egr valve and it did have a little wet on it, the coolant level has dropped some to. I scanned it and it didn't have any codes, no misfires or anything! Is it safe to say that the egr cooler has a small crack in it and its just starting to leak?
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Well, I've read a lot of threads on this problem! Try to do my own repairs, so I'm learning and not spending a lot of cash at repair shops.I have an 04 6.0 Super Duty Crew. Starting running rough on way home. Pulled over ,then it died.wouldn't start. Had towed home. Replaced ficm circuit board. No start. Replaced Harness,
icp...... ipr Sensors. Still no start. I noticed there is another circuit board inside ficm. Should I have bought the whole ficm unit?
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