2002. Starts easy enough, runs horrible, really rough and lots of white smoke. Will die if left unattended, doesnt matter if its plugged in or not. GPR was bad, replaced. Checked all glow plugs, all at .6-.8. After I start it, if I give it some throttle, I can get it past the rough running enough to get it going. Then I pretty much have to drive it and throttle it through a couple of gears and it clears out and runs fine.

Thank you for your help!

EDIT: I cleared the codes on it yesterday with code reader I picked up. Ran codes on it this morning after I got home. Here is what was pulled from Forscan. The water in fuel sensor is bad (got one on order). No matter how much I drain it comes back on, so assuming its bad anyway

===OBDII DTC None===
Successful DTC reading, no error codes found

Module: On Board Diagnostic II

===END OBDII DTC None===

===IC DTC U1027===
Code: U1027 - Engine RPM Data Invalid

Module: Instrument Cluster

Diagnostic Trouble Code details

At some time in the past a corrupt message was received from the PCM. Try clearing the DTC to see if this DTC re occurs. If it does then carefully check the SCP wiring and run the PCM diagnostic.

===END IC DTC U1027===

===IC DTC B1352===
Code: B1352 - Ignition key in circuit fault

Module: Instrument Cluster

Diagnostic Trouble Code details

Ignition key in circuit fault

--- Possible Causes --------
This DTC can be generated by:

-Open Key-In Ignition Switch circuit
- Battery short Key-In Ignition Switch circuit
- Battery short Ignition Switch RUN/ACCY circuit
- Suspect Ignition Switch
- Suspect Lighting Control Module.

===END IC DTC B1352===

===IC DTC U1262===
Code: U1262 - SCP Data Link Fault

Module: Instrument Cluster

Diagnostic Trouble Code details

SCP Data Link Fault

Operator Action

Run self test.

All CMDTCs

Fix all relevant DTCs then clear codes and retest.

Note:

DTCs that start with 'U' are faults which occur during module-to-module communication.

Modules should never be replaced based only on a 'U' code. These codes do not always indicate a problem, and can be caused by normal diagnostic functions, carried out on the vehicle.

===END IC DTC U1262===

===PCM DTC P1280===
Code: P1280 - Injector Control Pressure Failure

Module: Powertrain Control Module

Diagnostic Trouble Code details

Injector Control Pressure (ICP) circuit out of range low.

--Possible Causes--
- Open or grounded ICP circuit.
- Open VREF circuit.
- Damaged ICP sensor.
- Damaged PCM.

===END PCM DTC P1280===

===PCM DTC P0472===
Code: P0472 - Exhaust Pressure Sensor Low Input

Module: Powertrain Control Module

Diagnostic Trouble Code details

Exhaust Pressure Sensor Low Input

This DTC may be caused by :

Open circuit.

Short to Ground

Possible causes are:

Harness wiring

EBP sensor

PCM

Inspect connectors for signs of damage, water ingress, corrosion, etc.

===END PCM DTC P0472===

===PCM DTC P0118===
Code: P0118 - ECT Sensor Circuit High Input

Module: Powertrain Control Module

Diagnostic Trouble Code details

ECT Sensor Circuit High Input

This DTC may be caused by :

Sensor Previously disconnected.

Damaged or contaminated connector

Improper connection

Incorrect VREF.

Signal shorted to VBATT or vref.

Open Circuit

SIGRTN open circuit

Suspect ECT sensor.

Faulty or damaged PCM.

===END PCM DTC P0118===

===PCM DTC P0198===
Code: P0198 - Engine Oil Temperature Sensor Circuit High Input

Module: Powertrain Control Module

Diagnostic Trouble Code details

Engine Oil Temperature(EOT) circuit out of range high.

--Possible Causes--
- Open circuit.
- Short to VREF.
- Damaged sensor.
- Damaged PCM.

===END PCM DTC P0198===

===PCM DTC P1119===
Code: P1119 - Manifold Air Temperature Circuit High Input

Module: Powertrain Control Module

Diagnostic Trouble Code details

Manifold Air Temperature Circuit High Input

This DTC may be caused by :

Open circuit.

Short to power

Possible causes are:

Harness wiring

Manifold air intake temperature sensor.

PCM

Inspect connectors for signs of damage, water ingress, corrosion, etc.

===END PCM DTC P1119===

===PCM DTC P1140===
Code: P1140 - Water in Fuel Condition

Module: Powertrain Control Module

Diagnostic Trouble Code details

Water in Fuel Condition

This DTC may be caused by :

Short to Ground

Possible causes are:

Harness wiring

PCM

WIF Sensor

Inspect connectors for signs of damage, water ingress, corrosion, etc.

===END PCM DTC P1140===

===PCM DTC P0475===
Code: P0475 - Exhaust pressure control valve malfunction

Module: Powertrain Control Module

Diagnostic Trouble Code details

Exhaust pressure control valve malfunction.

--Possible Causes--
- Short to power.
- Open or grounded circuit.
- Damaged solenoid.
- Damaged PCM.

===END PCM DTC P0475===

===PCM DTC P0541===
Code: P0541 - Manifold Intake Air Heater Circuit Low

Module: Powertrain Control Module

Diagnostic Trouble Code details

Manifold Intake Air Heater Circuit Low

This DTC may be caused by :

Open circuit.

Short to Ground

Possible causes are:

Harness wiring

MIAH Relay

PCM

 

Lots of seemingly unrelated codes. These are the ones that came back?

I'd leave the WIF sensor wire disconnected and taped out of the way for now.

First item I'd check is the engine harness where it crosses the driver side valve cover en route to the 42 pin connector. Pull apart and look underneath for chafing and resulting short to ground on the VC.

While there pop the wire off the ICP sensor and look for oil. If wet replace with OEM Ford or IH, not aftermarket. The cheapies tend to have problems.

How much fuel in the tank? 1/4 or less can be a problem.

The rough running, dying and white smoke sound like fuel starvation. But if it clears up and runs normally after some driving that sounds like a clog on the in tank screens clearing off due to sloshing. A fuel pressure gauge monitored while operating would be best. Barring that observe the fuel volume from the fuel bowl drain. When running bad, turn off and key fuel pump back on (do not start) and watch flow into clean container so you can put it back. A helper to key on is needed there as pump will only run for 20 seconds unless engine starts. Do same visual check when running well.

How long has it been doing this?

 

Only recently. Ill check ICP today and wiring harness. If I can get the help Ill check the fuel. I drove it a few more times yesterday after clearning the codes. Ill pull codes before starting it today and see if they come back. I recently replaced the ICP sensor. I read that I should check the wiring for oil and then clean it if there is, so Ill check that as well.

It has about 1/4 tank in it. Ill fill it up.

Would a video of starting it help?

 

The P1280 code almost always indicates a bad ICP sensor. As stated, pop the connector off and look for oil. If it is wet, replace it. Even if it is not wet, having a P1280 code would make me want to replace it anyway.

 

Since I put a new one on it a couple months ago, I checked it. The harness plug had oil in it, so I sprayed it out and and put it back together.

Started great! a little white smoke, but good idle and warmed up and ran fine.

Ran codes and am getting all kinds of strange stuff.

Do these codes go back to a PCM failure or do I need to go ahead and pull the harness apart on driver vc and inspect? Ive never seen it come up with these.

Thank you all for your help! Its running good, but I wanna figure out the rest of this.

I forgot to include Im running a DP tuner F5 on it. I should have put that in my first post...



Code: P1536 - Parking Brake Switch Circuit

Module: Powertrain Control Module

Diagnostic Trouble Code details

Parking Brake Switch Circuit

Follow the routines in the service manual to resolve the DTC listed.

===END DTC P1536===

===DTC P0220===
Code: P0220 - TP - B sensor/switch malfunction

Module: Powertrain Control Module

Diagnostic Trouble Code details

TP - B sensor/switch malfunction

This DTC may be caused by :

Open circuit.

Short to power

Possible causes are:

Harness wiring

Idle Validation Switch

PCM

Inspect connectors for signs of damage, water ingress, corrosion, etc.

===END DTC P0220===

===DTC P0704===
Code: P0704 - Clutch switch input circuit malfunction

Module: Powertrain Control Module

Diagnostic Trouble Code details

Clutch switch input circuit malfunction

Shorted to power.

Suspect Clutch Pedal Position switch.

This DTC may be caused by :

Suspect PCM.

===END DTC P0704===

===DTC P0571===
Code: P0571 - Speed Control Brake switch circuit failure

Module: Powertrain Control Module

Diagnostic Trouble Code details

Brake switch circuit malfunction.

--Possible Causes--
- Operator intervention error.
- Open, short to B+ or GND in BPA circuit between PCM and switch.
- Open or short to GND between switch and power.
- Blown fuse.
- Damaged switch.
- Damaged PCM.

Note: Code will set if vehicle is not equipped with cruise control.

===END DTC P0571===

===DTC P0703===
Code: P0703 - BOO switch circuit fault

Module: Powertrain Control Module

Diagnostic Trouble Code details

Brake Switch B Input Circuit

This DTC may be caused by :

Open circuit.

Short to power

Possible causes are:

Harness wiring

Brake Switch

PCM

Inspect connectors for signs of damage, water ingress, corrosion, etc.

===END DTC P0703===

===DTC P0565===
Code: P0565 - Cruise control on signal malfunction

Module: Powertrain Control Module

Diagnostic Trouble Code details

Cruise control on signal malfunction

Follow the routines in the service manual to resolve the DTC listed.

===END DTC P0565===

===DTC P0566===
Code: P0566 - Cruise Control OFF Signal

Module: Powertrain Control Module

Diagnostic Trouble Code details

Cruise Control OFF Signal

Follow the routines in the service manual to resolve the DTC listed.

===END DTC P0566===

===DTC P0567===
Code: P0567 - Cruise Control RESUME Signal

Module: Powertrain Control Module

Diagnostic Trouble Code details

Cruise Control RESUME Signal

Follow the routines in the service manual to resolve the DTC listed.

===END DTC P0567===

===DTC P0568===
Code: P0568 - Cruise Control SET Signal

Module: Powertrain Control Module

Diagnostic Trouble Code details

Cruise Control SET Signal

Follow the routines in the service manual to resolve the DTC listed.

===END DTC P0568===

===DTC P0569===
Code: P0569 - Cruise Control COAST Signal

Module: Powertrain Control Module

Diagnostic Trouble Code details

Cruise (COAST) signal malfunction.

--Possible Causes--
- Operator intervention error.
- Worn or damaged speed control switch.
- Open, grounded, or short to power in SCCS circuit.
- Open or short in SC GND circuit.
- Open in Power supply circuit.
- Damaged PCM.

Note: Code will set if vehicle is not equipped with cruise control.

===END DTC P0569===

===DTC P0541===
Code: P0541 - Manifold Intake Air Heater Circuit Low

Module: Powertrain Control Module

Diagnostic Trouble Code details

Manifold Intake Air Heater Circuit Low

This DTC may be caused by :

Open circuit.

Short to Ground

Possible causes are:

Harness wiring

MIAH Relay

PCM

Inspect connectors for signs of damage, water ingress, corrosion, etc.

===END DTC P0541===

 

Glad to hear it is running better.

All of those codes are pretty random and not seen often. If it is running and driving well, I would not suspect your PCM is bad.

A lot of the codes you listed have to do with the cruise control. Is everything working fine there?

 

Ill drive it tomorrow, but yeah, everything has been working fine on it. Ill check the cruise, but it worked fine last week when I used it.

 

When was the last time you cleared all the codes? If you haven't in a while, do that first and then go drive it to see if they return.

 

Cleared them out. Here is what I have now. I just put milemarker hubs on it as the 4wd wouldnt engage on its own. Not sure if I need to worry about that code?

===OBDII DTC ===
Successful DTC reading, no error codes found

Module: On Board Diagnostic II
===END OBDII===

===IC DTC U1262===
Code: U1262 - SCP Data Link Fault

Module: Instrument Cluster

Diagnostic Trouble Code details

SCP Data Link Fault

Operator Action

Run self test.

All CMDTCs

Fix all relevant DTCs then clear codes and retest.

Note:

DTCs that start with 'U' are faults which occur during module-to-module communication.

Modules should never be replaced based only on a 'U' code. These codes do not always indicate a problem, and can be caused by normal diagnostic functions, carried out on the vehicle.


===END IC===

===PCM DTC P1140===
Code: P1140 - Water in Fuel Condition

Module: Powertrain Control Module

Diagnostic Trouble Code details

Water in Fuel Condition

This DTC may be caused by :

Short to Ground

Possible causes are:

Harness wiring

PCM

WIF Sensor

Inspect connectors for signs of damage, water ingress, corrosion, etc.


===END PCM===

===RCM DTC ===
Successful DTC reading, no error codes found

Module: Restraint Control Module
===END RCM===

===GEM DTC P1876===
Code: P1876 - Transfer Case 2-Wheel Drive Solenoid Circuit Open Or Short To Ground

Module: Generic Electronic Module

Diagnostic Trouble Code details

Transfer Case 2-Wheel Drive Solenoid Circuit Open Or Short To Ground

Follow the routines in the service manual to resolve the DTC listed.


===END GEM===

===ABS DTC ===
Successful DTC reading, no error codes found

Module: Anti-Lock Brake / Traction Control Module
===END ABS===

 

You have so much going on here.... so much random... I would look at the big wiring connector on driver's side of engine. Clean the connector. Then follow the big bundle of wires back to the plugs under the brake master cylinder.... look for a place wiring could be grounding out. Check your engine grounding terminals...pcm ground, etc.

 

Well, I checked as much as I could find, everything is in good shape. I havent gotten the cruise control stuff back, everything is working.

I know the WIF is valid, and the 2wd/4wd is valid as I would have to manually turn in the stock "hubs" when I put it in 4wd or it wouldnt engage.

Im gonna run it for a few days and check codes and see if anything comes back. After two days of running, the smoke and rough start is gone.

 

Cruise.... the sensor on the brake master cylinder is a known problem. There's a recall on it, as that's the sensor that was burning up a lot of gas burners. Took them years to issue the recall for diesel.... diesel doesn't burn as easy as a gasser... was there reasoning.