Hi Folks. Looking for some help/advice here. I have a 2004 Excursion 6.0 Diesel and it's not doing well. I've been looking around the forums but am still not sure exactly what's going on, and may have multiple issues (EGR cooler? Oil cooler? other?).

The worst issues started yesterday about 45 miles into driving, are constant hesitation and almost no power, both below 2000 RPM (very difficult to get moving at all), accompanied by white/blue smoke. The smoke goes away when we get up above 2000 RPM but it's still kind of rough, but has some power until we get down below 2000 and then it starts smoking/hesitating on acceleration.

Idle seems OK but smells different than usual (more diesel, not a noticeable coolant smell). Engine seems to rev OK in neutral without issue. During the roughness at lower RPM, even at freeway speed, it seems like we get a bit of funky diesel smell in the cab.

Over the last few weeks we've had periods of hesitation after coasting for a bit, and one instance of a LOT of white/blueish smoke for the first 5 minutes on a short trip after cold start.

Here's the current details, and Torque Pro OBDII readings:

Mileage: 109,000, all original - no engine work at all yet.
Primary (frame mounted) fuel filter change: 36,000mi.
Secondary (engine mounted) fuel filter change: 108,000mi.

Coolant level has been dropping over the last month or so. I replaced the in-line heater control valve above the engine as it was leaking some, but coolant still seems to be disappearing (though not as fast now). I've added over a gallon in the last month. Before that it was fine. I keep the level well below the add line. No leaking out of the degas tank, cap seems to hold pressure.

Removed EGR valve last weekend to inspect (on level ground overnight). It wasn't too dirty and no obvious moisture on valve or in manifold. Some caking of soot on bottom of valve. Cleaned and re-installed.

Engine has also been running really rough at start with no power until warm on cold starts after sitting for several days, for some time (stiction?), but fine after warm up (before current issue).

No MIL indicator, but I do have some DTC codes of:

• P0263 Cyl 1 Contrib/Balance,
• P0269 Cyl 4 Contrib/Balance,
• P0299 Powertrain,
• P0404 EGR control circuit range/perf.

The last DTC reset over 36,000 miles ago.

Also, sometimes (seems more frequent in hot weather), the turbo seems like it takes a long time to kick in when the engine is warm and we start out from a stop.

I rescued the wife last night when she was almost an hour away. We were able to limp home by keeping the RPMs up above 2000 and avoided as many stop lights as possible.

Torque Pro readings from that trip:

Driving (50 minute drive, hilly highway, avg speed 37mph, max 70mph, OAT low 50s °F):
Max Coolant vs Oil Temp Delta: 28.0°F (ECT 174.2, EOT 202.2)
Average ECT/EOT delta during trip: 16.5°F (ECT 180.6, EOT 197.1)
FICM volts Avg: 46.42, Min 45.0, Max 47.0
FuelInjectorPulseWidth Avg: 928.3, Min 575, Max 3654
ICP Avg: 1249, Min 575, Max 3655
ICP Volts Avg: 1.44, Min 0.7, Max 3.7
IPR Avg: 37%, Min 22.4%, Max 74.6%
Boost Avg: 3.7psi, Min 0, Max 19.4
Engine Load Avg: 37.3, Min 0, Max 93.3
VGT Duty Cycle Avg: 55.3, Min 31.8, Max 85.0

After trip, idle 653rpm
ECT 190.4°F
EOT 201.6°F
Boost -0.5
Fan 227rpm
FICM 46.5v
ICP 582.5
IPR 23.6
ICPv 0.8v
InjectorPw 952.0
VGT 85%
EBP 15.7psi
IAT2 159°F
IAT 77°F
VREF 5.0v

After trip, high idle 2500rpm
ECT 188.6°F
EOT 200.0°F
Boost -0.2
Fan 637.8rpm
FICM 46.5v
ICP 1400.5
IPR 35.2
ICPv 1.6v
InjectorPw 584
VGT 37.1%
EBP 17.4psi
IAT2 140.2°F
IAT 105.8°F
VREF 5.0v

Next day, cold, koeo
ECT 50°F
EOT 51.4°F
Boost 0.1
Fan 0rpm
FICM 46.5v
ICP 12.5
IPR 14.7
ICPv 0.2v
InjectorPw 0
VGT 0%
EBP 14psi
IAT2 49.0°F
IAT 51.8°F
VREF 5.0v


Anything obvious here, or some more items to check?

Thank you.

 

Your FICM volts are low - IMO it is getting weak

Your boost numbers look low. That and the P0299 might mean a sticking turbo.

The P0404 MIGHT mean a bad EGR valve, but it could be (probably is) related to the turbo.

Sounds like a turbo cleaning should be first on your list. I would also send the FICM in to Ed, but some folks don't seem to mind being at the low end of acceptable.

 

Thanks. I'll look at FICM and turbo first. Any concern about the ECT/EOT delta (it got to 28°F at one point on this last drive) or the coolant history?

 

How old is the Thermostat? the other numbers look fine except FICM is starting to show weak signs never want 45v anytime

 

Thermostat has never been replaced. The only thing that's been replaced under the hood are batteries, alternator, filters and heater control valve.

 

I would say work on getting it to run right first and then you can watch your ect/eot deltas. A proper test is to be running down the hwy unloaded for many miles to see what the temp spread is vs what the temps were while limping home while trying to stay over 2000rpm

 

OK Thanks fordF150Guy... Just wanted to be sure those weren't contributing to the main issue here with the power, etc.

This is my first real issues with this engine since we got it in 2005 (it's been great). I've got background with gas engines but this is new territory on digging into the workings of the diesel for me.

 

I believe you have just one injector missing. Get a live scan check.
Also, your delta's should be of concern IMO. Missing coolant besides? I'd expect to see 4-8 degree difference unloaded at 60 mph sustained. 10-12 if lightly loaded. A misfire shouldn't affect the deltas much if you can reasonable drive it.
A dry egr valve is a good sign but not proof of an egr crack.
Also, your vgt's should never get to 85%. Since you have a 299 underboost code, I agree with the others on a turbo unison ring issue. Stuck!

 

thats great that your truck has been trouble free for you and bonus points for having the means to read live data before something went sideways!! Like said before, start with a good turbo cleaning and wouldn't hurt to clean the egr valve and go from there. Good luck!

Edit: I see that you cleaned the egr last weekend. Wouldn't be a bad idea to give your cac boots a once over to check for cracks and also check the map sensor hose and make sure that the nipple it attaches to on the intake manifold isn't plugged shut with carbon.

 

OK, thanks guys. Sounds like a bunch of new things to look for/at and read about.

Also... I just went back and looked at my Torque Pro trip log... It looks like whenever I got to an idle the VGT goes to 85%. When I get over 2500rpm it drops to low 40s high 30s. (not sure what all that means though yet)

 

Most truck Idle at or around 85% it when you put a load to it nothing high out put reading 15% and 85 % low base value, mine sit's there too and I have good running Values. still keep an eye on it maybe a Turbo cleaning will help

 

 

Thanks for the video. I do see a few VGT = 85% during the trip log too, where I went from about 60mph to 50mph then 60 again, with rpm above 1600 the whole time. Boost during that same time went from about 9 to 3.9 at VGT = 85, then back up to 12 with VGT dropping to 38 then stabilizing in the 50s.

I'll be looking at the turbo cleaning info in the tech folder next.

 

Just noticed - was your primary fuel filter actually changed at 36,000 miles and you now have 109,000 miles?

Also, the coolant loss is an important thing to resolve. I would put pressure on it (small air compressor teed into a small degas bottle hose, along with a pressure gauge) and see how well it does hold pressure.

As r2millers said, you do probably have an injector or two starting to have problems.

 

I'd do what I call a 100,000 mile tune up.Clean the turbo and all the sensors.Change the fluids and filters...all of them.Do a blue Spring mod and send the FICM to Ed and get the Atlas 40 tune. Load test the batteries and clean the terminals.Ck the alternator.Go on a day trip down the highway and check your deltas while running the snot out of her and look for troubles and repair accordingly