My truck is dead again!

My E99 F35 PSD did the exact same thing it did about a year ago.

It suddenly acts like it is running on only one or two cylinders and then quits. It will restart but only run badly and then some times stop completely.

When it did this at the begining of last winter (in Fairbanks, AK so when I speak of winter I mean temperatures that stay at about 20 below).

I want to keep the truck so I pulled it in my shop and decided to fix all I could think of.

I replaced :

The injectors with rebuilt units from Swamps Diesel
The IDM with an up graded unit from Swamps Diesel
The HPOP from RiffRaff Diesel
Performed the 50 cent mod using the Ford parts
Dropped the fuel tank and cleaned it and performed the Hutch mod
Rebuilt the fuel bowl using low temp packings from RiffRaff Diesel
Replaced the CPS with one from RiffRaff Diesel
Replaced the Exhaust Pack Pressure Sensor (and made sure line was clear)
Replaced the Accelerator Position Sensor
Had the PCM reflashed by DP
Installed the RiffRaff cross over oil line
Installed the RiffRaff Regulated Fuel Return kit
Replaced the electric fuel pump
Bought the scanner from RiffRaff
Bought the programmer from DP

It ran great all summer!

Now, as soon as it gets cold ( 26 below) it falls apart and will start ok but only run on two or three cylinders.

I had to abandon it and have it towed to a repair shop! They won't get to it until monday so it is setting in this cold weather until then.

Any one got any ideas? What did I miss?

 

How many miles on your truck??
Your problem might be that you used the ford parts for the 50 cent mod instead of the quarters. Do you have any SES(Service Engine Soon) or CEL(Check Engine Light) while it is operating bad?
Did you do the Spin on filter outside the fuel tank with the hutch mod?
Did you add any fuel line heaters to the outside of your fuel lines to preheat the fuel?
Have you opened your fuel bowl drain valve lately to drain any water in the fuel bowl?
How many miles since you have changed the Fuel filter INSIDE the fuel bowl?
Have you cleaned inside the engine compartment with water lately and maybe some connectors might still have water in them?
As cold as it is up there have you considered wraping the fuel lines AND FUEL PUMP with some type of insulating material and zip tying it in place preferrably with a fuel line heater installed on the outside of the fuel line?
What is the condition of your batteries?
Have you treated your fuel with Diesel Klean to prevent gelling of your fuel?
What is the condition of your coolant? Have you tested it with test strips lately? I know you can not put ELC in the E99 because I have the E99 also.

 

Just changed the fuel filter. fiirst thing I checked was for gelling.
Have not washed truck engine.
Truck has about 180k miles
Oil was recently changed
Engine gets good and warm.
Batteries are good, thing starts right up and cranks fast.
Have not checked coolant. I know I am not using ELC
No check engine lights on or service lights.

 

sorry to screw with the problem at hand but why can't you use ELC in a E99?

 

I think the reason is because different injector cup materials and the coolant eats the injector cups.
To the OP. Did you add some Diesel Kleen to your fuel?

Did you get a CEL or SES WHEN THE PROBLEM WAS HAPPENING? A light that came on while you had the rough running and goes away later.

Re-read the questions in my above post and please answer all of them? Other people that will show up to this thread on Monday will be asking the same questions and if you have already answered them in a single post then they will know the current conditions you have. Just asking for info now.

Also how much fuel is in the tank and did you put a new pickup foot on when you did the hutch mod?
Did you add a spin on filter when you did the hutch mod?
Did you put any additives in your OIL?
How many miles ago did you do the injectors and tuner? Do you have at least 50-100 miles on it since then?

 

Kind of sounds like an IDM issue. Know anyone with a 7.3 you could swap IDM's with to test? Maybe use a scanner to buzz test when it's acting up to see if there's communication between the IDM and injectors?

The sealant used to install the injector cups on the E99 isn't compatible with the ELC. ELC will cause the cups to start leaking.

 

For what it's worth (and it may not be much) my otherwise perfectly running late 99 didn't want to start one wonderful morning, and when I did get it to run, it sounded like it was only running on a couple of cylinders. The driver's side UVHC had come unplugged. I did the 50 cent mod right then. That was over a year ago, and last week when I had a couple of "the brotherhood" helping me with my current issues, Peter mentioned that my one of my 50 cent modded UVHC's was coming unplugged again. It might be worth pulling those valve covers to check, and that won't cost you anything except standing out in the cold for 30 minutes or so.

 

Seconding what milman said, I had a Ford injector harness retrofit on one side and a quarter on the other and the Ford side came loose on me after a year. That being said, I did have a flashing CEL when it was missing. In your position and given what you're describing, first thing I'd do is ohm the injector pins at the tops of the VC plugs, quick and free.