6.0 missing - Replaced EGR Valve, problem exists...HELP!

[tank69]

VEHICLE:
2003 Excursion – 6.0L – 88k Miles – RBP 4” exhaust – AirRaid Intake – 8” lift – 38” tires – Ford Cetane additive

CLIMATE: The truck is in Phoenix, AZ, it’s cold now, 40 degree lows at night, if that.

PROBLEM:
At various times over the past year (11/08, 1/09, 7/09 & 10/09) I’ve had the “missing”, “sputtering” or “popping” problem. From 1750 to 2250 RPMS, when applying throttle, my truck misses and pops, big loss of power and I can smell unburnt diesel fuel. When this “missing” happens, I see black smoke coming from the exhaust. The turbo seems to wind up and down as well, like a low wine to high wine and back to a low wine, like it’s not getting enough air to properly operate. I cleaned the EGR valve a few times and the problem went away.

The past month, the problem continued and I cleaned the EGR valve, problem remained. I sucked it up and bought a new EGR Valve, the problem went away for three weeks. The past two days, the problem continues, however, not as bad as when I had the old EGR valve.
There are no engine lights or warnings when this happens. The truck starts fine. The problem sometimes happens when I begin driving or it starts after I’ve been driving awhile, it’s hit or miss.

REPAIRS:
I plan on resetting the computer in the morning, pulling the battery leads, and see if the problem reoccurs. If it doesn’t, I’m wondering if I have bad FCIM? Maybe I have some bad fuel injectors? I’m at a loss and very frustrated. I enjoy working on my own vehicle and this being my first diesel, I’m still a noob. There are quite a few diesel shops here in the valley, but If I can nip this in the bud myself, I’d be thrilled.

If you have any ideas or thoughts on what I can check/replace/repair/etc., I’m all ears. Thanks in advance for any help.

[joam081698]

I am having missing issues to as well as rough idle. I did an complete EGR delete kit from diesel tech and it has helped somewhat but still have trouble. Let me know if you get the problem fixed and how you did it. thanks

[International Tech]

Joam i forgot to tell you this as well:
remove the exhaust back pressure sensor and check the little port to see if it is plugged with carbon or soot. if it is replace it. also check the # on the turbo actuator there is a certain date code that should be replaced i don't remember the # off hand but i will look it up at work tomorrow and let you guys know.

[elm302]

wheres that sensor at?

[International Tech]

it's kinda tucked away underneath the driver's side air filter piping. if you look at the front of the exhaust manifold and follow the little tube all the way up you'll see it attached. also make sure the tube is clear by blowing a little air through it.

[tank69]

UPDATE -- UPDATE -- UPDATE -- UPDATE -- UPDATE -- UPDATE

I took the Excursion to Reliable Diesel a few miles away from my home in Mesa and they pretty much ruled out FI and/or FICM problems. They unplugged the EGR connector and the problem went away! I've tried my best to recreate the problem and I can't since we unplugged the EGR Valve.

So I took it in to have the turbo cleaned and that's when I found out some problems, my turbo is chewed up, the vanes look like someone shot them with buck shot and surfaces are pitted badly. I opted for a rebuilt turbo from Ford vs. rebuilding mine. I'll get my truck back on Monday, but it seems the entire EGR system on the 6.0 is a big problem.

[m-chan68]

Originally Posted by International Tech

Joam i forgot to tell you this as well:
remove the exhaust back pressure sensor and check the little port to see if it is plugged with carbon or soot. if it is replace it. also check the # on the turbo actuator there is a certain date code that should be replaced i don't remember the # off hand but i will look it up at work tomorrow and let you guys know.

2003 model years no longer use EBP input to set turbo boost, after the 06E17 recalibration update.

[International Tech]

make sure you replace the air filter otherwise you'll be replacing turbo again