Ford 7.3L Power Stroke (1999-2003) :: Surging During Warm Up And Some Low RPM Hesitation - No Start
Aug 15, 2017
My truck - early 2000 CC short bed, 300K miles
Background on my problem: I had a short list of long overdue maintenance and updates to do that time and money kept me from tackling. Found a little of both so I replaced the water pump, HPOP lines, re O-ringed the HPOP/IPR, deleted the AIH, replaced all of the brake lines in the engine bay, put new fuel lines to the filter bowl. All of this took me about 2 weeks so the truck sat with the batteries out for that long.
After buttoning it all up, it fired right up, a little slower than normal but figured that was air in the fuel lines, HPOP, etc. The only issue I had was the battery light stayed on. Thinking I had an alternator issue, I checked it and it was getting about 14.25v so figured that was good. I used it regularly for about 3 weeks, the light stayed on, and noticed some surging during warm up and some low rpm hesitation.
Then it stop dead on me driving down the road. Turns out it was all my doing, I had torqued the bolts on the water pump pulley but didn't use Locktite. The bolts backed out, shredded the belt, and ended up yanking the CPS wire harness out of the sensor. So that made total sense.
Fast forward another week, got new wiring pigtail and CPS (never replaced it before now) from a couple of the good FTE vendors. I am not sure about the wiring on the pigtail, my truck has a green, blue and brown/gray wires, the wiring diagram I found online showed green, blue and gray. I wired it connecting the brown/gray where the gray line goes (center contact) and closed everything up.
Another thing to mention is that I have an Edge Juice with Attitude that has been on the truck since '06. I lost that connector in the process and they were absolutely no support in trying to get me running again. Wouldn't or couldn't tell me which wire they connect to so I used the green wire which is the CPS signal wire to the ECM. Once I am running again, going to get rid of the Edge.
So that is where I am now. No start, I've been reading some of the "what to do" posts, the most likely is that I don't see the tach bounce when trying to start. So I want to check the wiring to make sure I have good connections to the CPS.
So I don't have any diagnostic software to read codes, etc. I really need to fix this myself and only have one set of hands most of the time. Not really sure what the problem was before it stopped running and now I can't diagnose the surging and hesitating.
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I have a 1999 f450 7.3 diesel that surges and will stall but will start right back up again and drive. It does this over and over but all ways gets back to the shop. The engine starts good when cold so glow plugs are working correctly. What I have done:
Fuel filter change, check electric fuel pump but have not replaced it. I have replace camshaft sensor.
What I have found d by inspection:
Throttle pedal has 2 electrical connections one for the IVS and one for the TPS. I have experience on the 7.3 IDI diesels but very little on the newer injection system.
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1990 Maxima. The car hesitates/surges occassionally after warm start, but only surges for about first 1/4 mile, then its OK. Sometimes it idles low, especially when I come to a stop and apply brakes hard. I believe the two issues are related. This has been getting progressively worse over past few years.
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So I was on my way to work on a semi-chilly morning here in Colorado. Every day as usual, a little upset in the morning, a little white smoke and after a good warm up i'm on my way. About 10 minutes up the road while accelerating on the freeway, I hit I guess the perfect RPM range (2000-2500) when all of a sudden my CEL came on. Right as the CEL showed up, the engine introduce to me a new skip and lost a bit of power. About 5 more minutes up the road, the CEL went off and the skip went away, unless in idle. I made it to work a few minutes later and the skip in idle was apparent for sure. I turned her off and just couldn't get her to turn back on. The injectors are just not firing, no smoke at all, they don't even sound like they're trying to fire almost like no signal to the whole engine.
I replaced the CPS, the IPR and unplugged the ICP to test if she'd go. I opened the fuel bowl and watched it fill up. I checked the HPOP level, it was almost full, maybe a quarter (between half) inch from the top. No codes.
She ran great until this, outside of needing glow plugs. When I was trying to get her started it was 60ish outside so I don't think glow plugs is the issue. It sounds like the Injectors are not firing at all, whatsoever.
I will note that I had a few fuses blow out of no where that I replaced, a trail light, OBD fuse and one other in the under-dash box. I had her dyno'd a few weeks back and the tech said she made great power but sounded like she had a little issue recovering from the high RPMs but I figured my injectors are tired.
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I have a late '99. It's been weak all summer. Took it to the dealership. They put it on the computer and said the only problem was bad injectors. Specifically #8. I replaced them all. It's still weak and now is starting to surge going down the road. I have my suspicions but I'm not a mechanic.
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I have a '01 7.3 Excursion 2WD. 220,000 miles. It has a 4" exhaust, K&N filter and Edge Reprogrammer set on emission illegal. It gets the best fuel economy and moves out very well for 8000 lbs. Recently, I started to feel a surge while making light throttle acceleration. For example, round a corner at 35 and try to gently resume the 45 Speed limit. It begins to accelerate and then cuts out or surges, sometimes several times. If I lay into it, it responds fine. I have serviced the air filter, the fuel filter, use synthetic Amsoil. I did notice a slight improvement after the service. Less frequent cutting out or surging. I also was in an area where Bio diesel is readily available. I added almost a full tank of B10 Bio and it seemed to work. Changed the fuel filter just after.
It has been cold for NC. This morning it was +14 when I started the truck. It seemed to finally catch on maybe 2 cylinders with lots o' white/ blue smoke. It cleared out in a few minutes and seemed to be hitting on all 8, or at least 7. Once it warmed up, it's fine. But I had the codes p0672, p0674, p0676, p0678. My question is: Is there a common thread in the fact that it appears that I lost 4 glow plugs on the same bank?
One arm chair quarter back's response to the surging, is that the under valve cover injector wiring harness may be breaking down, especially since the truck has 220,000 and the valve covers have never been off. I have a fresh turbo with the good wheel sitting ready. I have just been too lazy to swap it out. Would a fresh set of injectors be a wise choice, when I swap over?
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Ran torque for the first time on my f250, I used it for diagnostics to see if i can find out whats causing the surging. At a red light sitting idle it shows my icp at 705psi seems high to me? I'm running a dp tuner, it was set at stock for this run. It starts surging between 35-50mph and when coasting at about 60mph, surges during light throttle or maintaining throttle at low speeds. If i go about 70mph and up it runs like a champ. Ive changed the tps(entire pedal assembly), uvcg connectors, icp and pigtail. No CEL comes on, torque shows ipr is good, working on hpop pid. I just bought the truck last month and haven't been able to enjoy it much since it started doing this. ...
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My '03 7.3 is "surging" on idle. When warmed up, and idling, the RPMs will drop by 300 or 400 for a few seconds and then will correct and shoot back up. It cycles like this (every 5 seconds-ish) continually . I just put in a new IDM and checked the UVCH - is there a separate idle control mechanism that I need to have a look at? (2003, 7.3, 214K, stock).
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I have a 99 f-250 with about 250k miles. Truck is completely stock. It recently has developed a problem where when I start it in the mornings it surges at idle, 200 rpm or so. Sometimes it tries to die and did once but started back up. When driving it continues to rev itself up and is jerky. It runs rough and sounds like it could be missing on a cylinder. At other times it runs fine just like normal. Yesterday morning it started with these symptoms so I put in a new ford CPS. It ran great for about 100 miles that afternoon. This morning it started back with the same symptoms. The SES light stayed on longer than normal when I started it, but it went off. I don't have a scanner.
I thought it might be water in the fuel because this started the day after I filled it from my transfer tank. But the water in fuel light has never came on. I put a new fuel filter on it but it made no difference. Have pulled filter three times looking for water but never found a drop. Also pulled several buckets from the bottom of my transfer tank but found no water there either. Where to look next?
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I have an early 99 F-350 with 268K miles. It is bone stock right down to the factory exhaust. A couple months ago I started have a rough idle and surging while driving problem. I never got a check engine light but I borrowed a scan tool from a friend and pulled the following codes: P1690 (wastegate solenoid), P0381 (glow plug circuit malfunction), P0269 Cylinder 3 Contribution/Balance Fault, and P0284 Cylinder 8 Contribution/Balance Fault.
I did some research and everything I read said it was most likely the CPS. So I changed the CPS. The truck ran fine for for a few days but then it started acting up again occasionally. I noticed that most of the time when it acted up was at start up when the engine was cold and I also figured out that if I shut the truck off and re-started it (sometimes I had to do it 2 or 3 times) it would clear up and run normal.
A buddy of mine that has a 2000 F-250 said he had a similar problem with his truck and it ended up being the ICP sensor. We switched his ICP with mine and I changed my oil at the same time (because it was due for an oil change). My truck ran flawless for over 2-weeks (over 200 miles) so I put a new ICP in my truck. Note: my buddy did not experience any problems with his truck with my ICP in it.
I've put about 700 miles on the new IPR and the truck has started to act up again. Once again shutting the truck off & re-starting it will clear it up and still no check engine light. I took it to a local "diesel specialty shop" while it was running rough and they hooked it to their scanner and got P1280 (Inj. Control Pressure Low), P1690 (Wastegate Solenoid Fault), P0381 (Glow Plug Indicator), P0269 Cylinder 3 Contribution / Balance Fault, and P0284 Cylinder 8 Contribution / Balance Fault.
They never did anything other than hook it to a machine & check the codes but their diagnosis is my High Pressure Oil Pump is going bad and my #3 and #8 injectors are going bad. They recommended I let them replace all 8 injectors and the High Pressure Oil Pump. The problem I have is they can't give me a REASONABLE explanation as to why re-starting the truck a few times clears up the problem.
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I have a 45 min drive to work every day, all highway. Lately on the way home in the afternoon I have been experiencing a surging noise that seems to just happen while I'm doing hwy speeds. It sounds to me like the fan is tuning on and off. Is that possible? It comes on for a few min. And then off again. I have new icp ipr cps. New oil and filter and fuel filter.
Also I'm still having a battery light on and off issue while I'm driving. Is possible the two issues are connected. I plane on doing extensive search for a bad wire this weekend. Batteries and alternator have checked out and are fairly new.
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Recently since the weather has been cold. between 0-30 degrees or so. My 2002 7.3 with 161k on it is smoking a decent amount i think. far more than i ever remember it smoking thats for sure! anyways its a combination of blue and white smoke and it doesnt last long when the truck starts maybe 1 minute and the smoke stops.
But I also notice when i rev the truck maybe around 1200 rpms the engine shakes very bad. so i was thinking maybe a glow plug went bad making the engine seem like its missing. but even when its warm i rev it up to 1200 and i still feel the engine shake slightly. Maybe im just being picky when its warm? I need to test the glow plugs and go from there but i want opinions about that issue. the truck sits for 4 hour periods and every time i start it i have smoke. I will pay attention tomorrow morning if it smokes after being plugged in all night and post my findings.
My other issue and this typically happens when its below 20. sometimes i will go to accelerate after coming to a complete stop and the truck kinda has a very weak rev to it then just takes off like the tps took a break on me. sometimes i have had it jerk the truck when the throttle catches and other times it creeps at first then takes off like a boost of power.
lastly and this little issue happens most noticeable at 35 mph. i feel a surging im thinking this is related to the tps but i put the truck on cruise control and i still feel the surging. maybe this ties into my second issue? bad TC? ive plugged in my scanner and the only thing jumping out at me is the icp hunts about 100 psi or more at idle. i plan on doing a WOT test on the HPOP, ICP and IPR tomorrow and see if maybe this is just a weak hpop causing my issues.
Repairs i have done:
new 8th injector and all new injector seals about 25k miles ago.
new ipr
new icp
have CCV mod done and 4 inch turbo back exhaust
new map sensor
cleaned out the EBP sensor and tube but that was probably 40 or 50k ago now.
gray cps and i cant remember when i put that on.
gutted the EBPV
bellowed up pipes
no tunes the truck is factory as far as that goes.
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I have a 03 350 with a 6.0 . The truck starts fine in the morning and runs great all day as long as you don't shut it off. It's not going to start until the morning. It will crank over fine, the fuel pump seems to be working, its like there is no power to the injectors. I don't have a wiring diagram so not sure which relays are for injectors. Could the ficm be causing it? Is there a site where I can download a fuel sys schematic ?
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I have a 2000 Excursion with the 7.3L. We bought it in February of last year with 81,000 miles on it, and it has 111,000 miles on it now.
First problem:
It threw a code today: P0683 indicating a communication issue between the Glow Plug Control Module and PCM Communication Circuit. Other than the code, the truck isn't doing anything out of the ordinary today. Drove it about 40 miles, up to 80 MPH, problem three below did show it's head once, but other than that it ran great.
Second problem:
Ever since we've owned the vehicle it has done a strange surging/near-stalling thing (for lack of a better word) when it's started up. It only does it occasionally, and the problem seems to appear, and then go away for several weeks or months only to reappear. Here's how it goes:
- Start truck
- After starting the truck immediately begins to surge (rev?) and then nearly stall.
- It will do this over and over, about one surge/near-stall cycle per second, until I tap the accelerator, at which point it stops immediately. So far it has never stopped on it's own, but has always stopped with a tap of the accelerator.
Up until recently I chalked this up to "huh, that's weird" since the truck has otherwise run fine.
Third Problem:
Every once in a while the truck will hiccup while it's up to speed. It only seems to do it at highway speeds, typically between 55-70, and the hiccup typically only occurs once.
The first time I distinctly remember it happening was right after I had replaced the Camshaft Position Sensor (approximately 5-6 weeks ago).
While digging around online I found one other guy say his truck started doing the same thing after replacing the CMP in his F250 with the same little plastic gray one I used. So that problem might be caused by that part.
My Thoughts:
It seems like the run-away favorite for fixing problem one is to replace the GPCM. I've dug through a couple hours of forums this afternoon/evening, and it looks to me like the GPCM is the culprit the vast majority of the time when code P0683 comes up.
I'm thinking problem 2 might be an ICP issue. I can't find any previous forums anywhere that describe the exact issue I'm having - or really anything very close. Maybe it's out there, but I couldn't find it. So I'm really grasping at straws.
Problem 3 could either be related to the ICP (if problem 2 is an ICP problem) or it could be due to the new CMP I installed (the cheap gray plastic one from Autozone). It's possible the hiccup has been around longer than I think. Half the time when it happens (or does it?) I can't decide if it was a hiccup or a bump on the road I didn't see. I am sure it's happening at times, but there are other times I'm not sure if it was a hiccup or a bump I just didn't see. So I think it's possible it's been going on longer than I realize, and I noticed it that first time because I had JUST been under the hood and pretty finely attuned to how the truck was running as a result.
I'm about to hitch my 35' camper to this truck and haul it a few hours and I'm not feeling real confident right now. Problem 1 hit today, problem 2 is more prevalent than every right now, and problem 3 has been hiccupping for 5 or 6 weeks. I'd like to get at least problems 1 and 3 sorted out before hauling 8,000 lbs if possible.
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When I'm driving at highway speed and press the accelerator after coasting a bit, the engine stumbles then picks up and accelerates. The fuel bowl assembly is brand new as of 5 months ago, and I drained of any water last month when I changed oil. Truck is stock with 350k miles.
Apart from this issue, it runs well and idles smoothly. Injectors are healthy per a buzz test a powerstroke mechanic performed last year. What could cause the stumble off idle?
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My truck runs very rough and lacks power when cold, even during the Texas summer. Once it warms-up, everything is fine. It's almost like turning on a light switch. If it's plugged in for a couple/few hours, it's smooth as soon as it starts. I'm assuming it likes the oil once it reaches a specific temperature. What my problem is?
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I have hesitation as I accelerate especially starting from a stop. It will continue until cruising speed. Funny thing is when I put the cruse control on the hesitation stops and it runs fine. If I want to accelerate while on cruse the hesitation starts again until I let off the accelerator. Is it the TPS ? I changed it two months ago.
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E99 zf6 180k. Ts 6 position and 6637. Just found d out the oil was 25000 miles old and changed it. 400 mile trip followed by a few days in town with no problems. Shut it off warm and it won't refire. Takes 3 loooong cranks. Few minutes later it restarts hard but not as hard. Head out for a few hundred mile trip and it's running fine except all of a sudden "bucks" a few times within a couple hour window. I took data during the trip and never saw anything strange. Today a cold start, around town driving, and warm restart were all normal.
My thoughts are to
1. Verify steady fuel pressure (I only have a temporary gauge setup)
2. Check the fuel filter for oil.
3. Pull the valve covers to look for injector oil leaks.
#3, though, I dunno if it's worth it. Perdels look fine and icp seems to be about the same as it always has.
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I started my truck this morning and drove it quarter of a mile down the road to get some food letting it idle while in the drive through. While pulling away from the drive through window it started idling ruff . I drove it to the hotel and it ran perfectly normal until at a stop light and it started skipping again. If I put it on high idle it really starts skipping. Above 1500rpm it stops. What do you think?
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I have a 99 7.3, I took off driving the other day and after about 10 minutes the truck just dies like I shut the key off but everything was still on. I tried to restart it and it would fire for just a sec then die. I set for about 15 minutes and tried again it fired up and ran about 5 mins then the same thing. I had a buddy hook it up to his scanner and it has a p0605 and another icp code.. We changed the icp then erased the codes.. Ran some rest through the scan took with the truck running and no codes so we took it for a drive made it about 20 minutes away and same thing but this time has the p0605 code again. Could the pcm be bad? I also noticed the electric pump is always on all the time it will cycle at least 30 seconds every time the key is turned??
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I have a Tymar intake, magnaflow exhaust, a DP Tuner and I have Rosewood Diesel injectors.
I had a bad oil leak recently and it seemed to be coming from the turbo area so I changed all the o rings back there and deleted the EBPV system (I cut out the butterfly and welded the holes shut, cut the part of the pedestal that held the actuator because it looked like it was leaking and welded the oil holes in the pedestal that fed it. I left the actual EBPV sender in the pedestal and kept it connected to the harness)
After all that was done I checked the oil and it was low but still on the dipstick so I drove it to the local parts place to get some more oil, about 2 miles, because I wanted to check for leaks. It was not happy, ICP low code came up it was sputtering and jerking when stopped at a light. I got to the store and parked it, it took about 3 litres of oil and seemed to run pretty good after that.
But on the way home I noticed a bunch of white smoke, I figured maybe an injector was stuck. I started it a little later and no white smoke in the driveway so I thought maybe it had gotten lubed enough and had sorted itself out. That was a few days ago.
Today I started it and let it idle in the driveway for about 15 mins and no white smoke, I wanted to get it up to speed a little so I took it to do an errand that was about 10 miles away, lots of lights and a bit of highway. It would run fine while going at speed but as I would slow down for a light the ICP would go down to around 600psi and the white smoke would start, as sitting idling a huge cloud of white smoke would form (yes, I was that guy), once I could take off and get it running a bit harder it would go away again.
I am assuming that I have a stuck injector (or cracked), I have no oil in my degas bottle and it doesn't look like it is fuller than before. Seems like I may have used more fuel than I should have, but pretty hard to tell just from the fuel gauge.
I have tried a buzz test and they all sound the same, tried a Compression Contribution test, no codes from that.
How can I locate a stuck injector? If that's what it is?
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