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2001 Ford Excursion 7.3 limited 4x4. Randomly stalls while at Idle, or driving it down the road. It usually happens when i get it up to operating temperature. 2 months ago it would not start back up unless I pull the ICP out and reinstall. I try to unplug it and see if it starts, just cranks. If i remove the ICP and put it back in, it would fire right back up. I wanted to replace the ICP but i have my doubts. since the sensor is only about 6-7 months old, and i have replaced the pig tail connector, and it will not start unplugged. I replaced the IPR valve already and have the same stalls happening. I keep getting P1280,P0122, P0472,P0237.
I own every CPS made, all together I have 5 in the center console except for the NAPA version. Right now i have the OLD BLACK that came in them originally.
I have also changed the driver side valve cover/harness, changed the oil to fresh Rotella 15 40, drained the HPOP and filled back up with fresh oil. Rebuilt the fuel bowl because it had a leak, turned out the leak was out of the Dorman cap, so I purchased the OEM stock ford cap. Rebuilt FPR, installed the gold 62psi spring. Changed the IPR pigtail connector. It ran incredible for 700 miles. I thought that the IPR pigtail connector was the problem. The old cable looked real bad, and it was soaked in diesel from the cap leaking. When I first start it up, the ICP would read around 700-800psi, then balance out around 480psi @ idle. The lowest I ever seen it get was while decelerating to a red light, it fell to 420psi. The fuel pressure is measured post fuel bowl filter. Idle is about 59psi and I have not seen it go below 50psi since FPR rebuild. It was idling at 44 psi before the FPR rebuild.
Earlier this week, it died while driving through the neighborhood at about 20 mph. Would not start back up. Tried all my spare CPS's, all the usual checks,no luck, got it hauled home. The next day when i got off work, plugged in laptop to get readings, and it started. Turned it off, and back on 3 times within 10 minutes. The Borg Warner CPS was the last one i tried yesterday, so i removed it and put in a better brand CPS, back to no start. Even if I put the Borg Warner back in, still no start. So I am very lost, but do not want to give up.
Battery cables/batteries?? I dont know if these will cause the truck to stall like it does. PCM?
IDM? Wire Harness? I unwrapped wiring and searched for flaws and moved them around, wiggled and checked. HPOP??
P1280 ICP circuit out of range low
P0122 Accelerator pedal sensor circuit low input
P0472 Exhaust back pressure sensor circuit low input
P0237 Turbo boost sensor A circuit low input
You mentioned in another thread that you replaced your ICP and IPR with OEM sensors, so I think the next steps would involve figuring out how to eliminate these codes.
In the thread below, the same codes came up, and it ended up being the PCM:
I think I have read that thread before. All of the issues are the same. When i ran a buzz test, my tach was jumping at every pulse. Someone asked him if his tach was jumping, he solved the issue before he re tested to see. I just want to add that bit of detail. Going outside right now to remove the PCM and have a look at it. batteries are still charging in the garage.
If you hadn't replaced the IPR, that would be my first suspect. Have you checked for loose connections on all you joints? How 'bout where the harness feeds up over the VC on the driver's side? Any chafing of the wires there?
I replaced the IPR with a brand new Motorcraft brand back in April. I have checked connections multiple times.
This morning I took the PCM out. I will post some pics but I didnt really see anything out of the ordinary when is comes to boards. No burn spots, no chip installed, looks clean. There did appear to be some moisture in the pins, and a small area that looks like a burn, but i cleaned it out with electronic cleaner. Installed the PCM back in, checked the harnesses down where the PCM plugs in at the firewall. Put batteries back in and attempted to start, still crank no start. I want to add that the batteries were both in my garage getting charged overnight, the codes still pop up before I tried to crank. Could that be another sign that the PCM is bad?
Took the harness apart over the driver side VC and all the wiring looks good. Had my wife crank the engine while I wiggled and pulled wires, no change in the truck, no change on the laptop.
My next move is to remove the IPR just to check it out, make sure its o rings are ok. Then maybe another CPS just to quadruple check it. If I am still at a crank no start, I may go ahead and order a PCM from https://dieselecmexchange.com/ford/d...iAAEgIlHPD_BwE
They have the option for buying the PCM, I install it and if it does not solve the issue I can send it back for a full refund. If it does solve the problem, I send my busted PCM in and they give you a warranty for it. If anyone knows a better option for getting a PCM let me know. Thank you.
Just went outside and removed the Old Black CPS, installed the dark purple. Made sure to lube the sensor O-Ring and put die electric grease on the seal of the connector. Started right up. I have a warranty on my old black CPS, so just to make sure that it was bad, I re installed it. Same steps as the purple, lube o-ring and seal, Truck started with the Old Black CPS. I don't know how I feel about this.
I agree with you about the PCM. I think the best course of action will be to get the PCM, if it doesn't solve the issue, then send it back and order a new wire harness.
Quick update. As of July 9th I am still waiting on PCM. I ordered from http://dieselecmexchange.com/. 2 weeks went by after my order date so I called to see what the hold up was. They told me that they had tested a few that they had in stock and were not happy with the results. I asked if I could send my PCM to them and let them test, repair, and update. They agreed, emailed me a shipping label and I mailed it to them yesterday. Should be there by Friday or Saturday. Just wish they would have given me that option to begin with.
On my '03 EX, the cause for a Crank & no start situation was a dead IDM. I've had excellent customer service from Diesel Technology of Chattanooga. And so have others on this forum. Check them out. Jonathan is a stand up guy and will help you out with very fast turn around times.
On my '03 EX, the cause for a Crank & no start situation was a dead IDM. I've had excellent customer service from Diesel Technology of Chattanooga. And so have others on this forum. Check them out. Jonathan is a stand up guy and will help you out with very fast turn around times.
Thank you, I will look into that. What size tires do you have on your 20" wheels?
Got PCM back today from being repaired. They said they replaced 2 capacitors and put a jumper in, re-installed software. The truck started fine. First thing I notice is that my Edge Insight wants my Vin number. It has never asked for that before, so I guess something was done to PCM. I updated software on the Edge and put the vin number in using my PC. I left the truck running while I was in my office, when I came back I turned it off so that I could get my batteries strapped down, and put covers back on. I also put the PCM wire harness cover back on. Truck would not start.
Let it set for about 15 minutes, starts back up and is giving me my usual codes. Got under the hood and started wiggling wires while the truck is running. Remembered that PCM cover that i put back on. I went to pull the cover off and made it stutter when I touched it, pulled the cover the rest of the way off and the truck died. My PCM connector is bad.
I have been searching the internet, and I cannot find this connector/cable. Anyone know where I might find the replacement? If not I guess I will have to take out the harness and attempt to repair it.
There is a "connector catalog" in the 7.3L PSD Tech Folder, but I think this is part of the main harness and not available as a connector. You might be able to find a used one on eBay or something, but if I were in your shoes I would pull the harness into the engine bay and see about what is wrong or what needs to be repaired.
@ztodd377 just did this a couple weeks ago whole trouble shooting a no start issue. You could look up his thread and see a few images of how he got the PCM to the engine bay side. The images will be toward the end of his thread.
There is a "connector catalog" in the 7.3L PSD Tech Folder, but I think this is part of the main harness and not available as a connector. You might be able to find a used one on eBay or something, but if I were in your shoes I would pull the harness into the engine bay and see about what is wrong or what needs to be repaired.
@ztodd377 just did this a couple weeks ago whole trouble shooting a no start issue. You could look up his thread and see a few images of how he got the PCM to the engine bay side. The images will be toward the end of his thread.
Thanks. Looks like I will be pulling out a fender liner today.
