6.0 diesel excursion engine stalls

sajeev · September 17, 2005

hello ,

iam working on a 2005 6.0 excursion,engine quits

intermittently on return to idle after a hard

acceleration (hot or cold)or a cruising condition

with app near to close\part throttle area.i also got the cut off in neutral positionby pumping

the apedal in 1000-2000 rpm range.

the truck has done 25000km,well maintained .

checked and found crank shaft sensor output code

in koec ,cleared & re roadtested ,retrived sys pass.

checked pids & found icp goes down rapidly to 276

,180 etc..,ipr % goes up upto 75%,icp v .4,

rpm slows down to 0(no abrupt glitch),icpdes650,

vref 4.99,app ct 0%,ficm sync yes, sync yes,

ficmpwr lpwr hpwr 13,13,39v.,cmpf-no fault,

all other pids seem to be normal,ipr at 24% when motor idles normally.

c/o pcm reprogram with b39, replaced icp,replaced ckp,replaced cmp,replaced ficm,

replaced ipr,replaced pcm,replaced ebp,replaced

ficm&pcm (engine)harness,changed engine oil,

replaced tcc solinoid,checked for wiring chafes

before replacing harness.

removed icp &c/o air pressure test inthe high pressure line,at first i heard a gargling type sound with key off,on key on i started hearing

a wisthling sound from rear side of the engine

ifelt it was from the lhs cyl head ,i lifted the

lhs valve cover &used a hose to check the noise,

it was loudest at the rear.i didnt check the rhs

.ididnt hear any sound from oil dipstic tube .

as i commanded the ipr 9%-97% wisthing sound was

there,when i commanded 0% ipr the sound stopped,

again on commanding anywhere from 9%-97% i started hearing the sound.when i tried the test

next day the wistling sound never came.

i am tottaly confused because the pced says it

is normal to have asmall leak from the hp pump

shaft seal

please comment on the whole issue as i am new to

ford diesel ,i am more experienced in petrol.

we have sold only 7 units &have very little

ford diesels in this region (arabian gulf)

Keith Browning · September 17, 2005

Welcome to our community Sajeev, you are from Bahrain, an island country of the coast of Saudi Arabia? Just to satisfy my curiosity, do read and write in English or are you using a any type of translation software?

On to your post:

I noted all of the parameters that you listed but there is no mention of fuel pressure. For this engine to run well you will need to maintain a fuel pressure of 45psi or higher. You may not too far off looking for a high pressure oil leak as you might have an injector inlet o-ring starting to let loose. I have also seen the high pressure oil pump outlet fitting separate and leak. Generally these failures cause an engine to not start when hot if the leak is small. A large leak will cause a no start at all times.

I am working on an article about these seals and hope to have it finished very soon, hopefully soon enough to be of help to you. Let us know about that fuel pressure!

sajeev · September 18, 2005

i am an indian by nationality,working in bahrain

on contract basis,i can read write &uderstand english upto a reasonable level.i have done diploma in mechanical engineering on the academic side.

i did the fuel pressure test-50psi is maintained

even 10secs after cut off.

icp dies off,thats the only abnormal event i see on the wds, no codes ,pls tell me about the air leak sound characteristics

sajeev sankaran

ford tech

bahrain

Keith Browning · September 18, 2005

Try taking a look at this article: 6.0L ICP System Leaks

I realize that you have already performed the ICP air leak test but the test sometimes does not reveal a failure. Take a close look at the photographs. You may actually need to do some disassembly to fully inspect the system seals. What is not pictured are the crankcase to cylinder head oil feed tubes. You will want to take a look at those seals closely as well.

You sound as though you have good equipment and service manuals, are you using Ford publications and the WDS?

sajeev · September 19, 2005

i am waiting for my service managers approval

for dismantling the hp oilrails etc..

almost all sst's are available in our ford dealership,as for publication's we have paper& cd

versions, also we are connected to wdmo.

(hotline couldnt help in this particular case.)

i am working for the sole ford dealer for bahrain.

is it normal to have the sync showing yes even

after the engine stalls (key on),ficm sync goes to

off after 1-2 secs once the engine stalls.

it seems the dashpot function is not working properly either hydraulic or electroically

sajeev · September 27, 2005

at last ipulled out the manifold,lhs& rhs valve

covers,turbo etc. carried out the air pressure test again with the hp oil system naked,the air

leak was visible from the hpop quick release

connector,removed the oilpump & inspected the

quick connector,found o ring material damaged

(feathered-not cut). a big thankyou from my heart

.it is hard to belive that such a leak can cause

an intermittent quit at deceleration.we dont have the parts in our parts department ,as soon as the part arrives i will post the results

sajeev

bahrain

sajeev · September 27, 2005

at last ipulled out the manifold,lhs& rhs valve

covers,turbo etc. carried out the air pressure test again with the hp oil system naked,the air

leak was visible from the hpop quick release

connector,removed the oilpump & inspected the

quick connector,found o ring material damaged

(feathered-not cut). a big thankyou from my heart

.it is hard to belive that such a leak can cause

an intermittent quit at deceleration.we dont have the parts in our parts department ,as soon as the part arrives i will post the results

sajeev

bahrain

Keith Browning · September 28, 2005

I am glad that we were able to assist you! This is what this web site is all about and it's nice to see it in action. /forums/images/%%GRAEMLIN_URL%%/smile.gif