2007 F250 (EGR delete / Blue Spring / not studded)

***Truck has been running rough for a while. I’ve provided as much info as I can below, hope it helps you help me with ideas on what to do next. Then there’s a new problem below. Thank you!***

Feels like it’s cutting out/missing/choking/starved for fuel. Worse when it’s cold. Gets “better” once it hits 120-130 degrees, but still has the above symptoms.



BEFORE I GOT TORQUE PRO, I did the following (all Ford parts, everything torqued to specs):

Replaced both fuel filters, drained water, adding Archoil for fuel.

Changed oil (Rotella T6) and filter. Added Archoil.

Changed Transmission fluid and both filters.

Changed dirty IPR screen and cleaned IPR out (very dirty).

Did AIR test at IPR, didn’t hear anything. But I had to do it with cold engine as FICM bolts caused me problems getting them off.

Did test by touching starter wire to battery + terminal (BEFORE new batteries). I think it sounds ok. Here’s a link to video of it:
Cleaned EGR (though it’s supposed to be deleted—I need to figure out how to tell for sure—wondering because I was told my truck heads were studded but I’ve discovered they are not.) But it did come with an SCT tuner set for EGR delete.

AFTER I GOT TORQUE PRO:

Had a DTC for #8 injector contribution/balance, and a code for #6 (can’t remember which code). Did injector buzz test, no #8 buzz. Found that #8 injector plug had come unconnected, got it back on by removing valve cover to reach the wires inside. Tested the wiring for these two and it was ok. Injector DTC codes gone now. [I just tried to do another injector buzz test—my Forscan Lite won’t bring up the test…will update it and try tomorrow.]

Replaced dummy plug and top half of standpipe (didn’t have what I needed to get bottom half out, and had to get truck running asap). Since I didn’t hear any air leak I wasn’t too worried about it. Will replace bottom if I go into that area again.

Replaced both batteries.

Replaced two glowplugs and harness on driver side. (As codes show I still need to do 2 on passenger side) Some plugs were stuck and had to be drilled out—some debris fell in, but I read that it should go to bottom of pan. Hope this hasn’t/won’t cause issues.

New EBP sensor and tube (but not pigtail).

Tested Fuel Pressure as mentioned above, constant 58 psi. Didn’t change when truck felt like it’s starving for fuel. (Can Banjo Bolts ever be an issue? They’re downstream of where I had the gauge hose connected.)

Checked ICP, no oil leak.

Delta’s stay under 10 difference.

I do have oil on the upper hot charge hose rubber portion. May be a leak? I’m going to get new pieces.

AFTER ALL THE ABOVE, STILL HAVE THESE DTCs:

P0673 Powertrain (Glowplug #3) Goes back and forth from CURRENT (red) to PENDING (yellow) FAULT

P0675 Powertrain (Glowplug #5) Goes back and forth from CURRENT to PENDING FAULT

GREY SHADED FAULTS on TORQUE PRO are:

B1352 Body

P0230 Powertrain, Fuel Pump Primary Circuit (this concerns me, but fuel pump on lower rail was replaced about 4 yrs ago…could this code still be there from that?)

U1900 Network

--NEW PROBLEM—
Today my truck wouldn’t start after I drove it about 15 miles and let it sit 20 minutes. (And this was first time I left home without my Android/TorquePro!!) I had already been cranking on it 3x so I decided to wait another hour (in case hot/no start due to HPOP leak) AND unplug the ICP in case that was the issue. Doing both didn’t help with troubleshooting, but needed it to start and now draw batteries down. Fuel level is at ¾ tank. Oil level is OK. Got it home and it restarted OK 3 times for me. First time took a little cranking but not too much.

One thing I noticed…the day before I was at the same STEEP DRIVEWAY, but with the front of the truck pointed uphill, and it took a lot of cranking until it started. Today I parked with front of the truck pointed downhill and it wouldn’t start.

***Could being un-level cause a previously unknown problem to show up? And what might that problem be? ***

Once home, TORQUE PRO AT IDLE showed:

Battery 13.7-13.9 (Can go down to 10.7 while cranking)

ICP 1.2v (with ICP still disconnected) / 0.9v with ICP re-connected

IPR 32.9% (with ICP still disconnected) / 21.6% with ICP re-connected

HPOP 875 psi (with ICP disconnected) / 606 with ICP re-connected

FMP 50.0v / FICM Sync = 1 / FLP 13.5v

VGT 60.9% (I still need to learn about this one, what’s good range, what affects it)

MAP 15psi

Boost 0.7psi

Revs bounce from 682-704

EBP bounce from 16.8-17.1



Turned off and restarted…while CRANKING got the following:

Battery 10.7-11.4

ICP 1.0 then 0.9 and 0.8

IPR 42.9 then 30.2

HPOP 540 then to 667

FMP 49.5 / FICM Sync = 1 / FLP 12 then 11.5 then 11

VGT 0% until started

MAP 14.4psi

Boost 0.1 psi

Revs 0 until started

EBP 14.5


HOPE THIS IS ENOUGH INFO! IF I CAN GET FORSCAN WORKING I'LL UPDATE WITH NEW BUZZ TEST RESULTS. THANK YOU EVERYONE!!!

 

I suspect you have several issues.
Remove the cap from the secondary fuel filter bowl and crank the engine several times for 15-20sec. (key off!!) like in your video. (Let the starter cool down between the cranks for 1-2 mins.)
Watch the diesel fuel in the fuel filter bowl for air bubbles.

 

In addition to the above, if you had dirty oil in the IPR, then your injector spool valves are probably not performing as well as they should - ie sticking.

 

No RPM while cranking seems odd, but not sure how quick that registers when starter starts spinning.