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06-2-13 WHITE SMOKE, LACKS POWER, EXHAUST ODOR, SURGES, RUNS ROUGH, OR NO START - 6.0L
Publication Date: January 23, 2006
FORD: 2003-2005 Excursion
2003-2006 F-Super Duty
Some vehicles equipped with a 6.0L DI engine may experience white smoke, lacks power, exhaust odor, surges, runs rough, or no start. These conditions are caused by the injector spool valve sticking internally when cold. The concern is typically evident following a cold start and may last 3-5 minutes or longer as the vehicle warms up.
Diagnose these driveability concerns using the following Service Procedure.
NOTE: IF THE VEHICLE RUNS ROUGH OR HAS A MISFIRE WHEN THE ENGINE IS AT OPERATING TEMPERATURE, DIAGNOSE THOSE CONCERNS BEFORE PROCEEDING WITH THIS TSB.
NOTE: OIL ADDITIVES THAT INCREASE THE OIL'S VISCOSITY AND POOR MAINTENANCE CAN DELAY COMMANDED INJECTOR SPOOL VALVE RESPONSE. FAILURE TO CHANGE THE OIL ON A REGULAR BASIS AT THE PROPER INTERVAL WILL CAUSE THE INJECTOR SPOOL VALVE TO STICK WHEN COLD.
Refer to the owner's guide for recommended service intervals and oil grade/viscosity. Several oil changes with driving cycles may be required to "flush" the engine of residual additives and/or degraded oil.
NOTE: VEHICLE PERFORMANCE ISSUES RELATED TO FUEL QUALITY, MAINTENANCE AND AFTERMARKET MODIFICATIONS/ADDITIVES ARE NOT COVERED BY FORD MOTOR COMPANY WARRANTY.
Complete each of the following steps.
It may be necessary to keep the vehicle for one (1) or more overnight periods to verify all injectors that have a cold sticking concern. Customers with the cold driveability conditions listed should be advised it may be necessary to keep the vehicle in order to verify the repair. Technicians who become familiar with this procedure may be able to reduce the number of days some vehicles are held, based on experience in successfully identifying all the problem injectors using these steps.
Inspect engine oil quality, level and vehicle maintenance schedule, interview the customer as necessary.
Ensure oil is not unreasonably thick / fuel diluted / or soot contaminated.
Ensure correct oil grade / viscosity for vehicle use and ambient temperature.
If a concern is found with the engine oil, change the oil to "flush out" the undesirable oil, several oil changes with driving cycles may be required to "flush" the engine of residual additives and/or degraded oil.
Verify latest level calibration is installed. WDS version 37.4 and higher contains the calibration providing longer injector pre-start cycling at initial key on, extended injector cycling warms the injector and reduces spool valve oil latch upon cold start.
Verify proper operation of glow plug system following Powertrain Controls/Emissions Diagnosis (PC/ED), Section 5, AF, Glow Plug System Introduction. If concerns are found, repair as necessary and reverify the concern. If no concerns are found, continue to Step 4.
Validate fuel pressure is not less than 45 psi (310 kPa), and inlet restriction no more than 6 inches Hg when performing a 0-50 MPH Wide Open Throttle (WOT) acceleration. If concerns are found, repair as necessary. If no concerns are found, continue to Step 5.
COLD SOAK THE VEHICLE OUTDOORS OVERNIGHT. If this is not performed, incorrect readings will result.
Verify Engine Coolant Temperature (ECT) is no lower than 20° F (-7° C), or greater than 50° F (10° C). Accurate test readings can not be achieved when engine ECT is below 20° F (-7° C). The block heater may be used to increase coolant temperature if ECT is lower than 20° F (-7° C). ECT above 50° F (10° C) may limit concern severity and diagnosis time. If required temperature can not be met, do not continue with the TSB.
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