Fulltext TSBs

Technical Service Bulletins

TSB
06-2-13
  • WHITE SMOKE, LACKS POWER, EXHAUST ODOR, SURGES, RUNS ROUGH, OR NO START – 6.0L
Publication Date: January 23, 2006

FORD:
2003-2005 Excursion
2003-2006 F-Super Duty
2004-2006 E-Series

ISSUE:

Some vehicles equipped with a 6.0L DI engine may experience white smoke, lacks power, exhaust odor, surges, runs rough, or no start. These conditions are caused by the injector spool valve sticking internally when cold. The concern is typically evident following a cold start and may last 3-5 minutes or longer as the vehicle warms up.

ACTION:

Diagnose these driveability concerns using the following Service Procedure.

NOTE:IF THE VEHICLE RUNS ROUGH OR HAS A MISFIRE WHEN THE ENGINE IS AT OPERATING TEMPERATURE, DIAGNOSE THOSE CONCERNS BEFORE PROCEEDING WITH THIS TSB.

SERVICE PROCEDURE

NOTE:OIL ADDITIVES THAT INCREASE THE OIL’S VISCOSITY AND POOR MAINTENANCE CAN DELAY COMMANDED INJECTOR SPOOL VALVE RESPONSE. FAILURE TO CHANGE THE OIL ON A REGULAR BASIS AT THE PROPER INTERVAL WILL CAUSE THE INJECTOR SPOOL VALVE TO STICK WHEN COLD.

Refer to the owner’s guide for recommended service intervals and oil grade/viscosity. Several oil changes with driving cycles may be required to “flush” the engine of residual additives and/or degraded oil.

NOTE:VEHICLE PERFORMANCE ISSUES RELATED TO FUEL QUALITY, MAINTENANCE AND AFTERMARKET MODIFICATIONS/ADDITIVES ARE NOT COVERED BY FORD MOTOR COMPANY WARRANTY.

Complete each of the following steps.

It may be necessary to keep the vehicle for one (1) or more overnight periods to verify all injectors that have a cold sticking concern. Customers with the cold driveability conditions listed should be advised it may be necessary to keep the vehicle in order to verify the repair. Technicians who become familiar with this procedure may be able to reduce the number of days some vehicles are held, based on experience in successfully identifying all the problem injectors using these steps.

  1. Inspect engine oil quality, level and vehicle maintenance schedule, interview the customer as necessary.
    1. Ensure oil is not unreasonably thick / fuel diluted / or soot contaminated.
    2. Ensure correct oil grade / viscosity for vehicle use and ambient temperature.
    3. If a concern is found with the engine oil, change the oil to “flush out” the undesirable oil, several oil changes with driving cycles may be required to “flush” the engine of residual additives and/or degraded oil.
  2. Verify latest level calibration is installed. WDS version 37.4 and higher contains the calibration providing longer injector pre-start cycling at initial key on, extended injector cycling warms the injector and reduces spool valve oil latch upon cold start.
  3. Verify proper operation of glow plug system following Powertrain Controls/Emissions Diagnosis (PC/ED), Section 5, AF, Glow Plug System Introduction. If concerns are found, repair as necessary and reverify the concern. If no concerns are found, continue to Step 4.
  4. Validate fuel pressure is not less than 45 psi (310 kPa), and inlet restriction no more than 6 inches Hg when performing a 0-50 MPH Wide Open Throttle (WOT) acceleration. If concerns are found, repair as necessary. If no concerns are found, continue to Step 5.
  5. COLD SOAK THE VEHICLE OUTDOORS OVERNIGHT. If this is not performed, incorrect readings will result.
  6. Verify Engine Coolant Temperature (ECT) is no lower than 20 F (-7 C), or greater than 50 F (10 C). Accurate test readings can not be achieved when engine ECT is below 20 F (-7 C). The block heater may be used to increase coolant temperature if ECT is lower than 20 F (-7 C). ECT above 50 F (10 C) may limit concern severity and diagnosis time. If required temperature can not be met, do not continue with the TSB.
  7. Using the WDS/IDS with the Key On/Engine Off (KOEO), perform the injector electrical test (Injector Click Test).

    NOTE:VERIFY EACH INJECTOR RESPONDS WHEN COMMANDED. THE INJECTOR ELECTRICAL TEST WILL CYCLE THREE (3) TIMES.

  8. With the hood open, lean over the middle front of engine compartment. Listen and count each injector click. Record each cylinder number that does not make sound or is quiet in comparison to other cylinders.

    NOTE:THE INJECTOR ELECTRICAL TEST CLICKS THE CYLINDERS IN CYLINDER NUMERIC ORDER, NOT FIRING ORDER. SEE FIGURE 1.

  9. Repeat Steps 7 and 8.


    Figure 1 – Article 06-2-13

    NOTE:INDIVIDUAL CYLINDER PERFORMANCE IS RELATIVE TO THE PRECEDING CYLINDER IN FIRING ORDER. A LOW / NONCONTRIBUTING CYLINDER WILL IMPACT IN FIRING ORDER THE NEXT CYLINDER’S ABILITY TO FULLY RECOVER CRANKSHAFT SPEED TO THE NOMINAL VALUE (0). OBSERVED LOW CONTRIBUTING CYLINDERS MUST BE COMPARED TO THE PRECEDING CYLINDER’S CONTRIBUTION IN FIRING ORDER. THE GREATER THE DEVIATION FROM THE NOMINAL (0) FOR A CYLINDER, GREATER IS THE IMPACT ON THE FOLLOWING CYLINDER TO RECOVER, SEE FIGURE 2.




    Figure 2 – Article 06-2-13

    NOTE:WHEN MONITORING POWER BALANCE, LOOK FOR CYLINDERS SHOWING AS CONSISTENT LOW CONTRIBUTORS, NOT SINGLE OR INCONSISTENT DROPOUTS. INCONSISTENT DROPOUTS CAN BE DUE TO NATURAL VARIATION IN CRANKSHAFT SPEED, AND THE OPERATOR’S ABILITY TO HOLD THE ACCELERATOR PEDAL STEADY. SEE FIGURE 3.




    Figure 3 – Article 06-2-13

  10. Using WDS/IDS, KOEO, set up to start the Power Balance Test.
  11. Turn the key off (reset ignition switch to trigger glow plug cycle).
  12. Key On Engine Running (KOER) – Start the Power Balance test (Monitor only 5-8 seconds before proceeding to Step 13) and record low contributing cylinders (anything below -15).

    NOTE:IF THE ENGINE WILL NOT START, INCREASING THE ENGINE TEMPERATURE MAY WARM AND FREE INJECTOR SPOOL VALVES. MAKE CERTAIN ENGINE ECT IS NOT WARMED GREATER THAN 50 F (10 C). WARMING AIDS INCLUDE: ENSURING BATTERIES ARE FULLY CHARGED (AIDING STARTER CRANK SPEED AND GLOW PLUGS), PLUGGING IN THE BLOCK HEATER, CYCLING THE IGNITION KEY SEVERAL TIMES TO ENGAGE THE GLOW PLUGS AND INJECTOR PRE-START ELECTRICAL TEST.

  13. While still running the Power Balance Test, Push the # sign on the right side of the screen to disable the idle compensation strategy (monitor only 5-8 seconds before proceeding to 14). Record low contributing cylinders (anything below -15).
  14. While still running the Power Balance Test with the idle compensation strategy disabled (# sign pressed), increase the engine speed to between 800-900 RPM (monitor only 5-8 seconds before proceeding to 15) record low contributing cylinders (below -15).
  15. Replace injectors following Workshop Manual, Section 303-04C from all low contributing cylinders found in each of the Steps 8, 9, 13, and 14. Ensure all air is purged from high-pressure oil rails once the repair is completed.
  16. Validate repair. This often requires another overnight cold soak with the vehicle outdoors. If the concern is still present, repeat Steps 5 – 15.

PART NUMBERPART NAME
3C3Z-9E527-AEInjector Asy (MY 03 And 04)
4C3Z-9E527-AAInjector Asy (MY 04.25 And Up)

WARRANTY STATUS:

Information Only