Guys, I need some opinions

Been tracing a cold start issue on my 2003 6.0 with 113k miles. I have seemingly eliminated many possibilities, but I am still not sure what the problem is. Oil and fuel filters changed 200 miles ago, motorcraft used, 15w40 non-synthetic. No DTC's present. Bought used so I don't know how long this has been going on for...

Symptoms:
rough idle when cold. whole truck shakes, skips
white smoke, only initially
great lack of power for first 1-2 minutes of driving
Engine won't rev over 3000 rpm (In park, flooring it) <--doing so dumps white smoke
EOT ECT difference of ~10 degrees at full operating temp
slight loss off coolant
wet, sludgy spot under EGR valve

The last three symptoms point to EGR cooler failure and clogging oil cooler. BUT can this cause the first three symptoms?? The first three symptoms are really the pressing issues. I ordered a Bulletproof EGR cooler and plan to install it soon. I just don't think it will solve the cold start problem. Is this true or not?

The first three seem to point to injector issues, especially Stiction. Buzz test confirmed that injectors were OK but the problem is getting worse. (should I avoid driving the vehicle? Can it degenerate further and kill the injectors?) The fact that the issue TOTALLY clears up when the truck is warmed up points to stiction... but I have no experience so feel free to prove me wrong!

Do I have sticking injectors? I have no idea if the truck has been re-flashed with inductive heating. Also, I ordered Rev-x. Will I need it?? should i get it re-flashed??

So this is my problem guys. Could I have two major problems going on at the same time?? (just my luck) I'm running out of time and soon will just turn it over to the dealer (give up )

Thanks in advance to anyone who replies and to FTE, which has gotten me this far!

 

I would say most definitely you have an egr cooler telling you you'd better change it.the rough start and run is the engine burning off the water that's settling in your intake manifold. The slight coolant loss,and the wetness.under the valve are dead give aways.if you let it go you'll go to fire it up and you'll hear #7 piston trying to compress water.its not a.good sound.you can delete thecooler all together and be done with it a lot cheaper than a new one costs.

 

WHat was your FICM voltage? What is your EGR valve duty cyle(actual vs desired)?

 

have you checked your FICM voltage

shure sounds like the egr cooler maybe leaking although your spread is not that bad how wet was it in the egr chamber was it coolant

 

73Stang i don't think you have a egr cooler problem . You have an 03. Do you have the round cooler? if you do they rarely go bad , i have one it is welded now but was nothing wrong with it , they just don't fail. As to your other problems i have no idea what they are.

 

FICM checked out fine at 48 -48.5 volts. Forgot to mention that. GPCM was ok too.
I have no idea about the EGR duty cycle percentages. I know that I tested the EGR and then cleaned it out (gave increased power, but didn't solve the problem)

EGR valve MIGHT be bad. The gaskets on it are shot and haven't been replaced yet too... Unplugging the valve has no positive affect on cold starting

As for what Steelhead said, I don't think it has gotten that bad yet (hydrolocking?) Not much coolant has been lost...yet? But you seem to think the EGR cooler is my problem, right?

What about injectors???

 

The fact that the engine runs rough for the first 2 to 3 minutes and you run non synthetic oil 15w - 40w I would say it is stiction. I do not see the egr cooler reacting this way. If you do have a leak and it is possible I do not believe it would run rough for the first 2 to 3 minutes and then clear up. Let me ask a question? Is it worse the colder it is?

 

The colder it gets, the harsher the starts. I have it parked now for fear of injector damage.

How should I treat stiction? Will the sticking injectors have to be replaced eventually

 

There was a product that some here on the forum have tried called Hot Shot motor oil. Do a search here on the forum and read for yourself if you think it is worth a try. Some say it works some do not. It is an additive for the engine oil.

 

i have similar issues on my 03. did all of the goodies too.. and i also tried the oil additives. i used the rev-x brand. it worked great for the first 3 0r 4 cold starts, but then back to the same old stuff. today it was 60 deg. out ... she started great, maybe i need to move where it is warm all the time?

 

So wetness in the intake manifold is normal on an 03?.its got all the classic signs of a bad cooler.good luck 73stang which ever way you go,just don't let it go to long.mark your degas bottle and give it a look in a couple days.see how much coolant you're going through.

 

I'm definitely thinking injectors as they can cause white smoke too. Do a "sniff" test and see what the smoke smells like--sweet or fuel. Not saying it can't be the EGR cooler just that the round ones rarely fail.

 

Lossing coolant i THINK its the egr cooler

The loss of power when cols and the Smoke is injectors or injector Orings

Smoke at startup only ?Smoke at high rpms 2500-3000rpms? If so iam thinking copper crush ring bad . i had this and replaced all orings cost was under 40.00. Best money i spend in chacing this problem myself

 

Check fuel pressure if pressure is dead still while running no leak into fuel system from cylinder pressure If it bounces like crazy 5-10 psi you have a leak

 

On a hunch, and with help from you guys , I bought Rev-X

And it worked wonders! On the first start too (I didn't expect it to)!!

Soo doesn't that prove I have Injector Stiction? If so, should I go ahead and get the inductive heating re-flash? Because I've heard that Rev-X doesn't always have lasting effects...

Thanks!