2002 7.3 DIED WHILE DRIVING TODAY

lhud · #1 (**permalink**) 10-29-2009, 09:25 PM

Help Fellow FTE Folks,

Truck has 329K + and lately it has sort of hickuped numerous time to and from work - not a miss, but more like an electrical interuption, a jerking of the engine.
Today coming home, it just died. Pulled over swapped out a good (?) used CPS since the tack would not move when I tried cranking. Still no start.
Got the wife to bring me a brand new CPS (grey one) and installed that one, still no crankie. So I had it towed home.
At home I hooked the AE to it. Had a couple of codes from the overhead module problem I fixed last week with some loose surface mount resistors, so I cleared those codes - nothing else.
I tried the injector buzz test - would not do that test.
Tried the KOEO test - still nothing. Had to close the program each time to exit the program to do the nest test.
I have done both these tests in the past and they worked easily and responded.
Tomorrow if it does not rain, I plan to start checking fuses, etc. and whatever else you folks might suggest.
The batteries are new and the engine turns over very well.
Oil levels and fuel levels are good. Filter and oil change recently.
No check engine lights appeared.

Thanks for any suggestions.

mndiesel · #2 (**permalink**) 10-29-2009, 09:31 PM

Start with the fuses and maybe see if that area is wet. I have heard that sometimes the windshield can leak and it runs right down the firewall to the fuses. It has been wet down there the last week or so so I would start there.

lhud · #3 (**permalink**) 10-29-2009, 09:56 PM

I agree MNDIESEL, that's an easy starting point.

Thanks,

F350-6 · #4 (**permalink**) 10-29-2009, 10:00 PM

Tach will not bounce on the 02 model, so no luck there. No codes and no tests with AE. Any mods (chips) to the truck? Can you monitor live data with AE and just not run tests, or is it all shot?

flatbeder · #5 (**permalink**) 10-30-2009, 01:33 AM

subscribing

Rockrunner86 · #6 (**permalink**) 10-30-2009, 01:49 AM

Wierd. I would check for loose connectons (plugs, main harness plug also.)

This will be a interesting thread. Hope it gets figured out quickly.

riverrat41 · #7 (**permalink**) 10-30-2009, 08:21 AM

subscribing

Izzy351 · #8 (**permalink**) 10-30-2009, 08:34 AM

Yep -- you can't test the CPS with the tach like the pre-'02 models. No start means no HP oil or electrical, mostly. Can you see your ICP? When I changed out my injectors, it took several cranks to get it over 500 psi for it to fire. The second I hit 500, it fired. How are your batteries? They have to be over 10.5V to start.

lhud · #9 (**permalink**) 11-01-2009, 06:54 PM

Update!
Haven't forgotten about you guys.
Last Friday I finally was able to pull some codes - P1663, P1667 & P1668.
I could not however get the AE to perform the injector buzz test, so I unpluged the fuel bowl heater from the inside of the bowl - still no start.
Checked all the fuses under the steering wheel fuse box with a VOM - all O.K.; even swapped a couple of relays there as well - still no start.
HPOP oil level is fine. Also replaced the accelerator pedal since I had a spare - still no start.
I also made sure my fuel pump was coming on when the key was turned on; also opened the drain valve on the fuel bowl and ran the pump - noticed I had more flow with the pump on than without, but was not impressed enough with the pressure difference.
I had ordered a new Walbro, 255LPH pump and it came in late Friday after I had the truck towed to the diesel shop. Would have replaced it but did not get the chance.
Since it is my work truck I wanted to attempt to fix it before having to turn it over to my local diesel shop (not the stealership) who has a very good reputation around here before it got too late on Friday of last week. With rain called for on Saturday, I was not going to have a full weekend to check things out - bad deal.
So, on Saturday I started reading through my Ford shop manuals, expecially the "Powertrain Control / Emissions Diagnosis manual. Wow, it has a lot of good stuff.
I am now suspicious of the fuel pump with the high miles on the truck, so my "Guess List" is going to be:
1. Fuel Pump Failure
2. UCVH Failure or Failures
3. IDM
4. PCM
I know this is long, but since there are numerous posts for similar problems and no real follow up with the solution, I wanted to keep you up to date.
I expect the shop to call me tomorrow or Tuesday at the latest with their diagnosis.
It frustrates me that I gave up too easily with the trouble shooting procedure, especially after I read through the manual.

Thanks Fellow FTE Guys,

F350-6 · #10 (**permalink**) 11-01-2009, 07:22 PM

If you've been reading your PC/ED manual, then you should know the first thing you need to do at this point is check for power going to the IDM. Swap the IDM relay, and go ahead and check for voltage as called for in the diagnostic tree.

I don't think your issue is fuel pump or UVCH issues. You can have a UVCH plug come completely off and the truck will still start and run.

lhud · #11 (**permalink**) 11-02-2009, 06:51 PM

Update
Spoke with the shop today - I'm reading in between the lines a little.
First, they said they swapped the IDM with another unit (supposedly a working unit) and still no start.
I asked if they pulled any DTC's and the man said he would check and call back.
No call back, so I called mid-afternoon.
They had pulled four codes: P1663, P1667, P1668 & P1670. I had pulled the same except for the P1670.
They said they found water in my engine's valley - now way. Maybe a small amount of diesel fuel from opening the fuel bowl to disconnect the heater.
They said the IDM connector plug was filled with water and asked if I had pressure washed the engine or driven through some heavy water or possibly left the hood up while raining. No to all the above. Still do not believe water was in the valley.
So they plan to continue their diagnosis with the PCM and they sprayed down the IDM plug with "electrical spray" attempting to dry some of that out for tomorrow's work.
As F350-6 says, they should be checking the power on both sides of the IDM as well as the IDM fuses/relays, etc.
With the DTC's they pulled, one would think they would follow the manual's suggested procedures.
I have read threads talking about how easily water can find its way into the IDM area in the wheel well - there's got to be a better location for such a "animal". Also, one thread revealed a loose IDM ground.

Will continue with this tomorrow.

Thanks,

fat j · #12 (**permalink**) 11-02-2009, 08:53 PM

hey guys im new to the forum just had a quick ? i have a 01 e-350 power stroke and the problem iv been having is code p306 . the van will not start in the morning if i dont plug it in overnight and when im driving it smokes white on take off and hesitates like it has serous turbo lag iv already relplaced fuel filter /batterys/glowplugs/wire harness under vale covers bothsides for the injectors left side clip on harness was broke that fixed problem with staring and helped cut smoke down to but couple days later it startsd again any thing would help me rite now thanks

F350-6 · #13 (**permalink**) 11-02-2009, 09:09 PM

Quote:

Originally Posted by fat j

hey guys im new to the forum just had a quick ? i have a 01 e-350 power stroke and the problem iv been having is code p306 . the van will not start in the morning if i dont plug it in overnight and when im driving it smokes white on take off and hesitates like it has serous turbo lag iv already relplaced fuel filter /batterys/glowplugs/wire harness under vale covers bothsides for the injectors left side clip on harness was broke that fixed problem with staring and helped cut smoke down to but couple days later it startsd again any thing would help me rite now thanks

Welcome to FTE fat j. Please start your own thread so we can work through this and not confuse the issues. My first thought in your case would be the GPR, but the P0306 means you should have a GPCM which would set a different code? Anyway, start a new thread of your own and we'll get this figured out without confusing the original issue in this thread.

USAF CCM · #14 (**permalink**) 11-03-2009, 01:12 PM

Quote:

Originally Posted by lhud

Update
Spoke with the shop today - I'm reading in between the lines a little.
First, they said they swapped the IDM with another unit (supposedly a working unit) and still no start.
I asked if they pulled any DTC's and the man said he would check and call back.
No call back, so I called mid-afternoon.
They had pulled four codes: P1663, P1667, P1668 & P1670. I had pulled the same except for the P1670.
They said they found water in my engine's valley - now way. Maybe a small amount of diesel fuel from opening the fuel bowl to disconnect the heater.
They said the IDM connector plug was filled with water and asked if I had pressure washed the engine or driven through some heavy water or possibly left the hood up while raining. No to all the above. Still do not believe water was in the valley.
So they plan to continue their diagnosis with the PCM and they sprayed down the IDM plug with "electrical spray" attempting to dry some of that out for tomorrow's work.
As F350-6 says, they should be checking the power on both sides of the IDM as well as the IDM fuses/relays, etc.
With the DTC's they pulled, one would think they would follow the manual's suggested procedures.
I have read threads talking about how easily water can find its way into the IDM area in the wheel well - there's got to be a better location for such a "animal". Also, one thread revealed a loose IDM ground.

Will continue with this tomorrow.

Thanks,

Subscribing, since I have a 2002 and getting ready to hit the 100,000 mile mark soon. Hope this gets remedied for you soon. V/r Les

wrtaz · #15 (**permalink**) 11-03-2009, 05:42 PM

I'd guess the wire harness under valve covers. Had mine come unpluged a few times and no it will not run. Do a buzz test on the injectors you may find one side not responding. You may also try to have someone push on the plug and see if it'll fire back up. Try both sides.