PLEASE HELP!!! 2003 F250 Random Stalling
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PLEASE HELP!!! 2003 F250 Random Stalling
Ok, new to Ford-Trucks.com. Here is my issue. Bought bone stock 2003 F250...was not running when we got it. Prior owner said he resealed HPOP and I verified there is good pressure...We put in all new stock injectors, glow plugs & wires, ICP, IPR, FICM, Blue Spring, Fuel Pump and Cam Sensor. After fighting with the Fuel Regulator (FYI, there is an o-ring that apparently goes behind the black seat sleeve on the 03 models), truck roared to life and sounded great. All readings look good. FICM, Sync, ICP, HPOP, Temp,...Took out for maiden voyage and when we got up to temp it started to sputter around 2000-2500 rmp and stalled a few times, but started right back up. No Smoke, No Codes. In drive, when cold, it throttles up to 3200-3500 rpm smoothly...so it seems to happen when up to temp. Could this be due to the system being opened up for injectors and it is still having to purge air out of the systems? If so, how long does that take. My only other thought is fuel related. Fuel Pressure is reading 100+ from pump and 65+ in the bowl when reading from the port on the bottom of the bowl...so I think pump is good. When we opened the upper bowl, there were a few bubbles coming from the inlet side, but very little. Is this normal? I have done the bubble test with the starter wire and, no bubbles, so I think Injectors are seated properly...these bubbles are coming from the fuel inlet line when the bowl is filling. Could that air possibly increase under load (2,500 rpm) and cause sputtering and/or stalling. If so, what is the best way to diagnose it? Any advice would be greatly appreciated.
Update: Was able to test fuel pressure under load and it held steady at 68 psi +/-. Someone recommended replacing the ICP sensor so I ordered and OEM that should be here Saturday. In the mean time I disconnected the ICP. It was a long crank again, but finally started. At first it throttled up with no hesitation...up to 3,500 rpm...sounded smooth. Took down the road but got similar results as before. When it warmed up, it sputtered and stalled with heavy acceleration...but it started back up. Seemed to run fine under 2,000 rpm. My question is, with the ICP disconnected, would it still have the sputter and stall symptoms if it were a bad ICP? Also, after disconnecting the ICP, I got cam/crank open circuit codes...is that because of disconnecting the ICP?
Update: Was able to test fuel pressure under load and it held steady at 68 psi +/-. Someone recommended replacing the ICP sensor so I ordered and OEM that should be here Saturday. In the mean time I disconnected the ICP. It was a long crank again, but finally started. At first it throttled up with no hesitation...up to 3,500 rpm...sounded smooth. Took down the road but got similar results as before. When it warmed up, it sputtered and stalled with heavy acceleration...but it started back up. Seemed to run fine under 2,000 rpm. My question is, with the ICP disconnected, would it still have the sputter and stall symptoms if it were a bad ICP? Also, after disconnecting the ICP, I got cam/crank open circuit codes...is that because of disconnecting the ICP?
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Another update...replaced ICP with OEM, resealed IPR, all readings still look good. Video shows cylinder contributions during sputtering. Acts like the hpo is creating a leak under load or higher rmp's...is that possible? I have done the bubble test and dont see exhaust gas coming back through upper fuel bowl but could that still happen under load? Based on this, what can I eliminate and what should I continue to go after? Still no codes...took out for a drive and when it got up to 2500+/- rpm it want to stumble...eventually lost power, and stalled. Waited a few minutes and started back up. Hobbled back to house fine as long as its under 2000+/- rpm. Really frustrated!!!
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" FYI...it is 06 cab with 03 motor...thus the updated gauges.
Sorry, I am posting on multiple boards trying to get some help.
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Sorry, I am posting on multiple boards trying to get some help.
Cargo Master
Joined: Oct 2007
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From: BoCoMo
To answer your questions on how long to purge air out of the fuel line system, it may take up to 50 miles to do that.
Your screens may be clogged up in your fuel tank.
Is your engine a7.3 or a 6.0?
Your screens may be clogged up in your fuel tank.
Is your engine a7.3 or a 6.0?
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So for those interested...it was the injectors. The new set from Alliant solved my issue. Very frustrating that a brand new set of injectors was bad and cost me a lot of time and money. Lesson...don't go cheap on injectors.
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