Looking for help on a tough problem - Ford Powerstroke Diesel Forum

 
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post #1 of 5 Old 06-25-2014, 05:57 PM Thread Starter
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Looking for help on a tough problem

First post here.

I joined looking for some ideas on a tough problem we are having with a 2004 E-350 6.0. The van has 80K and a really good maintenance background. Oil changes are done by the dealer, etc.

The problem is an intermittent rough idle, when you cycle the key often it will run perfect. Sometimes it will still run rough even after a key cycle so it isn't 100%.

The van has had 2 FICMs, 4 ICPs, 2 IPRs, and 2 EBPs in the last 5K miles.

The van is all stock except for an EGR bypass. All the parts on it are Motorcraft.

We have looked at the scanner until our eyes crossed. Here is what we have found:

When it runs good
ICP 575 at idle
IPR 22

When it runs bad
ICP 875 at idle
IPR 31-32

Our take is the IPR is doing its job perfectly and the issue is the ICP reporting to high a pressure at idle causing the IPR to open more and creating a rough idle. As you can see several ICPs were put in and the problem keeps coming back. It can happen hot or cold.

What else besides the sensor could be causing an intermittent high ICP reading?

Any other ideas, because we're stumped?

Thanks in advance.
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post #2 of 5 Old 06-25-2014, 06:23 PM
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What are the readings for FICM voltage and what is the status of the EGR valve itself? Have you tested the static and dynamic fuel pressure? Are the connections to the FICM secure? What is the status of the injectors? Is there any smoke from the tailpipe?
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post #3 of 5 Old 06-25-2014, 08:03 PM Thread Starter
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Quote:
Originally Posted by vashaman01 View Post
What are the readings for FICM voltage and what is the status of the EGR valve itself? Have you tested the static and dynamic fuel pressure? Are the connections to the FICM secure? What is the status of the injectors? Is there any smoke from the tailpipe?
FICM voltage 48.5 always. The EGR valve is plugged in but just laying there, this is the unmonitored software version so it doesn't throw a code. FICM connections have been checked several times and no issues. No smoke from the tailpipe. Injectors are all looking real good, I don't have the values off the top of my head but we have gone through them many times, but I'll recheck them tomorrow and post some values.

I haven't done a fuel pressure test, I'll look at that tomorrow as well. What is the logic behind that question just so I understand where you're coming from?
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post #4 of 5 Old 06-25-2014, 08:09 PM
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Clogged up EGR could cause a rough idle or surge at times. If it is clogged it will hinder the actuation of the valve itself causing all sorts of issues. The fuel pressure can certainly cause a rough idle if it's dropping below 45 PSI. The fuel pump could be getting weak or there is not enough pressure in the fuel lines themselves. Also inside the fuel tank is a sediment filter which gets clogged lowering the fuel pressure by not allowing the pump to suck as much fuel as it needs. The issue may not be electrical at all, could be fuel related or EGR.
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post #5 of 5 Old 06-25-2014, 08:28 PM Thread Starter
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Quote:
Originally Posted by vashaman01 View Post
Clogged up EGR could cause a rough idle or surge at times. If it is clogged it will hinder the actuation of the valve itself causing all sorts of issues. The fuel pressure can certainly cause a rough idle if it's dropping below 45 PSI. The fuel pump could be getting weak or there is not enough pressure in the fuel lines themselves. Also inside the fuel tank is a sediment filter which gets clogged lowering the fuel pressure by not allowing the pump to suck as much fuel as it needs. The issue may not be electrical at all, could be fuel related or EGR.
The EGR has been bypassed with a sinister kit. The valve is still there and plugged in but just sitting on the intake.

I'll check the fuel pressures out tomorrow.

Thanks for the response.
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