2003 6.0 Excursion rough idle then stall. Any Ideas? - Diesel Forum - TheDieselStop.com
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6.0L Power Stroke Engine and Drivetrain Discussion of the 6.0L Power Stroke diesel engine and drivetrain in the 2003-Up Super Duties and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 6.0L Power Stroke engine.

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Old 03-07-2012, 06:39 PM   #1 (permalink)
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Question 2003 6.0 Excursion rough idle then stall. Any Ideas?

I was driving down the express way the other day when all of a sudden out of nowherethe engine started losing power. It was not a quick loss of power but is very slow over 20 seconds loss of power until the engine eventually stalled. it would not restart. I had to have it towed back to my house. When I tried to start is the next day it started right up. it idled very rough like it was missing on at least 1 or 2 cylinders until eventually after about a minute or 2 it stalled and would not restart just like the day before. this process repeats itself. I can start it once then after it stalls the first time it will not restart no matter what I try unless it sits for a period Of at least 6 hours.

now I'm no diesel expert but to me this sounds like a fuel problem. My thoughts are either fuel filters they have about 20,000 miles on them, I was going to change them on the next oil change (about 600 milesfrom now). or I heard that the FICMs on the 6.0s are prone to go.

It is a 2003 ford excursion, all stock, with 205,000 miles. any help would be appreciated. If you have had an issue similar to mine or you have an idea as to what could be causing the issue I would greatly appreciate to hear about it.

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Old 03-07-2012, 07:49 PM   #2 (permalink)
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Fuel filters may or may not be your problem but since you're waaaaaay overdue to change them, start there and see what happens. Low fuel pressure is the #1 killer of injectors.
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Old 03-07-2012, 07:57 PM   #3 (permalink)
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Ya I planned on changing them in the first place, I guess I shouldn't have waited for one more oil change. I am going to change them tomorrow as well as test for proper fuel pressure afterwards, Cuz this perticular Excursion has already went through one pu earlier in its life.

Will update how it goes in the next couple days.
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Old 03-07-2012, 08:13 PM   #4 (permalink)
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Was it belching out tons of black smoke also?
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Old 03-07-2012, 08:22 PM   #5 (permalink)
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the first time it stalled when I was going down the express way it was 5 o'clock right during rush hour so I was concentrating on just getting to the side of the road and not being killed, so the first time it started losing power I cant say for sure because I didn't see, but when I start it now and I get a minute of idle outta it there is very little smoke. no more than normal for a cold diesel
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Old 03-08-2012, 01:10 PM   #6 (permalink)
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So by rush hour I assume you were doing low speeds? First thing to check is to se if your EGR valve is stuck open.
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Old 03-08-2012, 01:25 PM   #7 (permalink)
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We changed the fuel filters, got it running it idled a little rough just like before, we reved the engine to 1500rpm for 30sec, and as soon as we let off it immediately stalled, and won't restart, no sputtering or anything. Just cranks and that's it. So changing the fuel filters didn't change anything.

If it sits for quite a whike, you can start it back up but if it idles for to long or you touch the throttle at all it stalls out.

Very Weird.
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Old 03-08-2012, 03:29 PM   #8 (permalink)
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1) Make sure you are only using the OEM oil filter style w/the OEM cap. NAPA / Wix filters with the big dome cap are a no no.
2) Get it scanned for codes. Not all codes illuminate the dash lamp.
3) Check your fuel pressure. Should have at least 45psig at all times.
4) Pull your EGR valve and inspect. If it's severely coked up or won't seat completely, replace it.
5) Check your ICP and IPR while cranking. The easiest way to do this is with a Scan Gauge 2. You can pick one up for about $140 and is a great little tool. You need to make at least 500psig oil pressure before the injectors fire.
6) Pull your FICM relay, remove the secondary fuel filter cap, and have somebody crank the engine while you watch for bubbles. A bad injector seal will allow combustion gases into the fuel rail and displace the fuel. The bubbles will be confirmation on combustion gases.
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Old 03-08-2012, 04:30 PM   #9 (permalink)
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Quote:
Originally Posted by dieselmac View Post
1) Make sure you are only using the OEM oil filter style w/the OEM cap. NAPA / Wix filters with the big dome cap are a no no.
2) Get it scanned for codes. Not all codes illuminate the dash lamp.
3) Check your fuel pressure. Should have at least 45psig at all times.
4) Pull your EGR valve and inspect. If it's severely coked up or won't seat completely, replace it.
5) Check your ICP and IPR while cranking. The easiest way to do this is with a Scan Gauge 2. You can pick one up for about $140 and is a great little tool. You need to make at least 500psig oil pressure before the injectors fire.
6) Pull your FICM relay, remove the secondary fuel filter cap, and have somebody crank the engine while you watch for bubbles. A bad injector seal will allow combustion gases into the fuel rail and displace the fuel. The bubbles will be confirmation on combustion gases.
yeah I have a friend coming tomorrow that has one of those really expensive snap on computers that you plug right into the dash. he's gonna scan for codes as well as monitor all the systems as we try and start it and we can get it started as it stalls. and he's also bringing a fuel pressure gauge were gonna check the pressure for sure tomorrow as well. I will also try your suggestions as well.

I will make sure to update you all tomorrow on how things go and if we learn anything. If you guys have any other suggestions it would be greatly appreciated.

thanks again all.
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Old 03-13-2012, 01:02 PM   #10 (permalink)
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After fiddleing around for a couple days, trying some of ur suggestions and it was to no avail. Did a proper Fuel pump pressure check too, even with fuel gushing out the connections still hit 55psi which is fine. New development now though.

We can hear cavitation in the pump when we key it.

But there are no visible leaks so air in the line could be our problem. Now to find out how the air got in there and why its not purging it self out.

This is turning out to be the nightmare I thought it would be...

Were stumped for ideas.
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Old 03-15-2012, 10:18 AM   #11 (permalink)
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Ok, our friend with the snap-on tool shows the HPOP only producing 250-300 psi.

So it looks like its finally had its last days. I guess 200k miles for a stock 6.0 HPOP is not bad lol

We'll replace that and she should be back on the road. Will keep posted.
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Old 03-18-2012, 05:54 PM   #12 (permalink)
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holy cow this is EXACTLY what happened to my 03 6.0 powerstroke let me know PLEASE after you replace the HPOP if it worked I had in mind to replace all my injectors please update if you can...
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Old 04-14-2012, 10:09 PM   #13 (permalink)
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update???? same problems
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Old 04-14-2012, 11:49 PM   #14 (permalink)
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update???? same problems
Oops, forgot about this post. Ya the HPOP was the problem. I've drove it about 2500 miles so far and it seems to be working perfectly.

Thanks everybody again for all the help.
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