I was wondering if any one knew of a checklist of reasons that cause "chugging", rpm surge, puffs of black smoke, and the occasional stall all at the same time. I have had this problem for a while, I will fix it and it is fine for a while(maybe a month or so) then it comes back. So I am trying to cross off the things I've done and focus on what else I havent done yet. Any ideas will be helpful.

 

Thick oil ie:cold oil. The thick oil causes the icp sensor to call for extra pressure. Hpop meets the need. Ex: engine desired- 2400psi. Hpop output- 2400psi psi. Therefore causing injectors to push extra fuel into cylinders that is not needed. Which leads to surging, black smoke, and intermittent stalls until oil temp is high enough to thin it out some which would lead to lower Hpop output and less fuel delivery.

 

EGR Valve? Have you pulled and cleaned it?

 

+1 ^, Sometimes the EGR valve just needs to be replaced also, but cleaning (properly) is the first step.

Also clean the MAP sensor hose and the EBP tube.

Always a good idea to make sure you have good system voltage and that the alternator and batteries are healthy.

If you can't resolve it with the posts above, then get a scangaugeII (or equivalent) and start troubleshooting with it.

 

I have also seen the EGR valve cause this.

 

Billy 6.0 - yes I had the same problem last week and it was the EGR. You need to clean the valve really well so that it move freely. Also replace the gasket & oring kit - you can get this from auto parts store. I coat the orings with engine oil before putting it back.

I notice that you have Scanguage II. If so you need to monitor the EGR to ensure that it is operating as it should. I would suggest using the following parameters. You should get about the same value for both at constant speed.

EGR Valve Position Desired (%)

TXD: 07E02209D2 RXF: 0462050906D2 RXD: 3010 MTH: 00647FFF0000 NAM: EVD

EGR Valve Position Measured (%)

TXD: 07E02209FE RXF: 0462050906FE RXD: 3010 MTH: 00647FFF0000 NAM: EVM

 

According to the mechanic that serviced the truck before I bought it he welded a plate inside the EGR valve in order to delete it. I have not personally seen the weld. Is there a link on how to pull it out so I can take a look. I'm getting ready to order a new oil cooler(old one is shot) maybe I can take care of them both at the same time.

 

Not sure where the MAP sensor tube is located. Just cleaned the EBP tube over the weekend while I was changing the thermostat.

The batteries are brand new just got them last week when my ficm went down and had to have it repaired.

I checked the voltage with my scangauge 2 and it was 13.8-14. not sure if that is ok or not. I read in some other posts that value is ok.

I replaced the EBP sensor a few months ago when I was having this problem and it fixed it. Is there any certain sensors you think I should be looking at?

Thank you for all of your help.

 

map sensor is on passenger side mounted on top of ac housing with 3 screws to a bracket. Map sensor is bolted with 2 torx screws to that bracket. the tube goes from the map sensor down to intake manifold again on passenger side between turbo and intercooler tube. it is a 1/4" hose appx 12" in length.

 

Bruce I set these into my SG and the egr desired does not work for me I double checked the code and looks correct.
Do or have you used this code ? Does it work for you ?

 

Edogsf350 - These parameters work for me. As you can see that the parameters are almost identical. Did you get your codes from a guide named " 2003 - 2007 Ford Super Duty 6.0L Powerstroke ScanGuage II XGauge Codes " - updated: May 11, 2012? If so then the EGR Desired "EVD" is not correct for it is the same as the "EVP".

Check your code again and make sure that is it the same as what I have indicated.

 

Ok that's the answer....EVP is calculated ( PCM flash ) and doesn't show up on my SG or my AE