Fulltext TSBs

Technical Service Bulletins

TSB
06-22-3
  • WHITE SMOKE, LACKS POWER, EXHAUST ODOR, SURGES, RUNS ROUGH, OR NO START – 6.0L
Publication Date: October 23, 2006

FORD:
2003-2005 Excursion
2003-2007 F-Super Duty
2004-2006 E-350, E-450

This article supersedes TSB 06-2-13 to update the Service Procedure and vehicle model years.

ISSUE:

Some vehicles equipped with a 6.0L diesel engine may experience white smoke, lacks power, exhaust odor, surges, runs rough, or no start when cold. These conditions are caused by the injector spool valve sticking internally during cold engine operation engine oil temperature less than 70 F (21 C). The concern is typically evident following a cold start after an overnight soak at ambient temperatures below 70 F (21 C) and may last 3-5 minutes or longer as the vehicle warms up. The concern completely disappears after driving and the engine oil temperature (EOT) is greater than 150 F (66 C).

ACTION:

Diagnose and address these driveability concerns using the following Service Procedure. This procedure includes a fuel injection control module (FICM) recalibration that adds an injector cycling sequence after every shutdown. This will prevent cold injector spool valve sticking.

Customers will be able to hear the injectors cycling after shutting off the vehicle, so a customer information sheet has been included with this bulletin. It is important to demonstrate the injector cycling routine, explain the noise as a normal part of the reprogramming, and deliver a copy of the the information sheet to the customer.

For Econline 6.0L, a wiring harness modification is needed to allow the FICM to power itself down when the vehicle is turned off, instead of being controlled by the key through the powertrain control module (PCM) power relay.

SERVICE PROCEDURE

NOTE:(SERVICE ADVISOR OR SERVICE MANAGER) IT IS IMPORTANT TO MAKE SURE THE CUSTOMER KNOWS THE CYCLING SOUND AFTER SHUTDOWN IS CYCLING THE INJECTORS AND IS NORMAL. BE SURE TO DEMONSTRATE THE POST-SHUTDOWN CYCLING SOUND TO THE CUSTOMER AND EXPLAIN THE NOISE IS NORMAL.

  1. Reprogram the FICM to the latest calibration using IDS release IDS 45.9 and higher or IDS 46.1 and higher. This new calibration is not included in the VCM 2006.11 DVD. Calibration files may also be obtained at www.motorcraft.com.
  2. E-Series vehicles ONLY, the FICM wiring modification MUST be performed.
  3. After reprogramming, start the engine then turn off the key and verify injector cycling for 30 seconds after engine shutdown.
  4. Test-drive the vehicle to get the engine up to full operating temperature in order for the new injector shutdown cleaning cycle calibration to be effective. At least 12 AGGRESSIVE ACCELERATIONS from 25-50 MPH (32-80 KM/H) should be adequate to get the EOT up to 180 F (82 C). After test drive verify EOT is greater than 180 F.

    NOTE:SOME ROUGH IDLE AND HARD INITIAL START IN EXTREME COLD TEMPERATURES (BELOW 20 F OR -7 C) IS ACCEPTABLE AND CAN EVEN BE EXPERIENCED ON NEW VEHICLES. FURTHER REPAIRS SHOULD NOT BE ATTEMPTED IF THE VEHICLE IMPROVES IN ACCELERATION/DRIVE AWAY.

(Service Advisor Or Service Manager Recommended Steps)

  1. Advise and demonstrate to the customer the injector cycling sound when the engine is shut down. It is IMPORTANT to make the customer aware that the cycling sound after shutdown is normal.
  2. Print a copy of the customer information sheet and give it to the customer for future reference. (Figure 5)

Econoline Fuel Injection Control Module Wiring Modification:

Two (2) wiring splices are needed to modify the FICM power path to enable injector post-cycle. Both will be made using the Rotunda 164-R5903 Crimp Tool Kit.

From this kit, we will be using:

  • Four (4) shrink tubes
  • Two (2) medium-size crimp barrels
  • Additional tools are:

  • The crimp tool
  • The heat gun
  1. Disconnect the negative battery cable.
  2. The first splice will be under the power distribution box (PDB). To access the wires to be spliced, remove the box and battery cable covers.
  3. Remove the B+ cable from the PDB terminal.
  4. Uncouple the PDB from the lower half by releasing the four (4) lock tabs with a flat blade screwdriver. Then flip the box over to access the wires to be spliced.
  5. Locate Circuit 3049 (black with light green stripe). This is the PCM keep-alive memory wire. We will be tapping into this wire to feed the FICM relay coil, which is circuit 361 (red wire connecting to the FICM relay socket). (Figure 1)


    Figure 1 – Article 06-22-3

  6. Locate an easily-accessible place where the two (2) wires can be spliced together. You may need to gently pull the wires out of the main bundle for access to allow enough slack in the wires to make the splice.
  7. Cut through both wires. Cutting the red wire closer to the main harness bundle may help to provide enough slack to make the splice.
  8. Strip both cut ends of 3049 (BK/LG) and the relay side of 361 (RD). Do not strip the harness side of 361.
  9. Twist Circuit 361 and 3049 together, then insert into one end of a medium crimp barrel.
  10. Slide heat shrink tubes onto the harness side of each wire. Make sure to do this before crimping, which is the next step. You may need to shorten the shrink tube to allow exposure of the stripped end of the wire on the main bundle for crimping.
  11. Using the middle anvil of the crimp tool, crimp 361/3049.
  12. Insert the other end of 3049 into the other side of the crimp barrel.
  13. Using the smallest anvil of the crimp tool, crimp 3049.
  14. Slide the shrink tubes into place over the crimp barrel and half way over the blunt cut end of the harness side of 361.
  15. Heat both the shrink tubes evenly, taking care not to singe any wires. Heat until melted sealant flows out of both ends, this will ensure that a weatherproof seal is achieved. (Figure 2)


    Figure 2 – Article 06-22-3

  16. Reassemble. Torque the PDB cable nut to 80 lb-in (9 N-m).
  17. The second splice is at the X3 connector on the FICM, located in the rear against the dash. This is the widest of the three (3) connectors. (Figure 3) To access this connector, remove the air cleaner lid and move the coolant bottle out of the way.


    Figure 3 – Article 06-22-3

  18. To start, remove the three (3) bolts attaching the coolant bottle to the fender and cowl.
  19. Move the coolant bottle over for access.
  20. Loosen the intake boot hose clamp and unclip the air cleaner lid.
  21. Disconnect the mass air flow (MAF) sensor connector.
  22. Remove the lid.
  23. Unclip the X3 FICM connector by squeezing the top and bottom tabs while pulling straight out.
  24. Remove the tape from the tail of the 90 cover.
  25. Unclip the cover by prying at the side seams.
  26. Carefully remove the tape from the first 6 inches (15 cm) of the harness branch leading away from the connector. (Figure 3)
  27. Locate Circuit 814 (white with black stripe).
  28. Locate the four (4) circuit 876 wires (green with light green stripe).
  29. Choose one (1) 876 (GN/LG) wire which runs close to circuit 814 (WH/BK).
  30. Locate an easily-accessible place where the wires can be spliced together.
  31. Cut through both wires.
  32. Strip both cut ends of 876 (GN/LG) and the connector side of 814 (WH/BK). Do not strip the harness side of 814.
  33. Slide heat shrink tubes onto the harness side of each wire. Make sure to do this before crimping, which is the next step. If you forget the heat shrink, cut the splice out and re-crimp. DO NOT disassemble the connector for any reason, as it is very difficult to re-assemble.
  34. Twist Circuit 876 (GN/LG) and 814 (WH/BK) together, then insert into one end of a medium crimp barrel. Using the middle anvil of the crimp tool, crimp 876/814.
  35. Insert the other end of 876 (GN/LG) into the other side of the crimp barrel.
  36. Using the smallest anvil of the crimp tool, crimp 876 (GN/LG).
  37. Slide the shrink tubes into place over the crimp barrel and half way over the blunt cut end of the harness side of 814 (WH/BK).
  38. Heat both the shrink tubes evenly, taking care not to singe any wires. Heat until melted sealant flows out of both ends, this will assure that a weatherproof seal is achieved. (Figure 4)


    Figure 4 – Article 06-22-3

  39. Tape the branch.
  40. Reinstall the 90 cover and tape the tail. Reconnect the X3 connector, making sure both top and bottom latches click
  41. Reposition the coolant bottle and torque the bolts to 89 lb-in (10 N-m).
  42. Reinstall the air cleaner lid.
  43. Connect the MAF sensor.
  44. Tighten the intake boot hose clamp, torque is 35 lb-in (4 N-m).
  45. Reconnect the negative battery cable, torque is 18 lb-ft (25 N-m).

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage

OPERATIONDESCRIPTIONTIME
062203A2004-2006 Econoline 350/450 6.0L: Perform Fuel Injection Control Module Wiring Modification, Reprogram The FICM, Includes Time To Road Test (Do Not Use With 12650D, 12650D84, 9601A)1.8 Hrs.
062203A2003-2007 Super Duty, 2003-2005 Excursion 6.0L: Reprogram The FICM, Includes Time To Road Test (Do Not Use With 12650D, 12650D84)1.0 Hr

DEALER CODING

BASIC PART NO.CONDITION CODE
9E52742



Figure 5 – Article 06-22-3


NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company’s on-line technical resources.

Copyright 2006 Ford Motor Company