So I’m at a absolute loss! I installed full force stage 1 injector to my 2000 f250 and installed the tuner they stated was required. And ever sense once the truck warms up it starts trying to die out fluctuating between about 500 and 750 rpm’s sometimes higher. Ipc voltage running between .8 and under 1 volt at idle and ipr % dropping down to 10% and 14-15%. I checked wiring harnesses and nothing seemed out of place. Seems to be the worst when in park or neutral sometimes going away entirely when it’s in drive or reverse but not always. Whenever I turn off high idle it is likely to kill the engine. Today was the first time I gotten a contribution fault code on cylinder 8 and it only come up when the engine was up to full operating temp about the same time it will start surging. But the truck starts fine no smoke hardly any blow by at all especially for 250,000+ miles. Also I had run it the 150 mile stated to get air out of hpop system. Anyone have a idea?

 

@Powerstrokef250 , welcome to the FTE!

Sorry to read about your troubles, but a couple of things come to mind...

• Warm EOT can often times expose issues since the oil is hot and lower viscosity.
• IPR DC at ~10% on a warm engine when looking at EOT ~200° is normal. If it is rising and falling from 10% - 15%, that is an indication of a problem.
• ICP is a lot easier for FTE'rs to evaluate when it is relayed in PSI units of measurement.
• RPM should be steady. It might vary a bit (10 points or so) while watching it on a data log or live.
• Visual inspections of the wiring harness are good, but you are likely not going to find any small issues unless you are using a multimeter.
• A contribution fault code is a sign of where you should be looking, similar to other codes that cause a check engine light or are stored.
• Even with one bad injector, the engine will run. They have been known to run on one bank.
• Have you performed a buzz test on a cold engine?
• Do you have a Hydra or another tuner chip?
• If you have a Hydra, try turning the ignition to ON, switch the Hydra to 00, wait 3 seconds, turn the ignition to OFF, wait 3 seconds, turn the ignition to ON, start the truck and see how it does from there. The truck will run and idle on this "bypass" tune in position 00 even if the injectors are modified, but it will not be optimal.

After reading your post and going through the different issue indicators you have told us, you may have gotten a bum injector or two from FFD. I am no master mechanic though, so I fully encourage you to troubleshoot the issue utilizing the tools you have on hand and the guidance that may be provided here in order to identify the fault and resolve it.

 

Has the truck been run long enough to work air out of the fuel and HP oil passages after the injector install? If so, what is your fuel pressure doing?

Also, surge in this forum usually refers to turbo compressor surge which is not what you are experiencing.

 

Yes I have preformed a buzz test and had come up with nothing before it would give a 1 and 7 open/short to ground but that went away and the 8 contribution code appeared. I have put the recommended 150 mile on it to get the air out of the system I’m going to try the fooling the hyda tune suggested and of that does not work I have the now harnesses and valve cover gasket’s I will try. After that pretty much everything other then the hpop and pcm in new that has anything to do with injector function.

 

We wish you the best of luck, but before spending too much money on parts and services, give FFD or the vendor you bought the FFD injectors a call and talk to them about your symptoms, OBDII readings and observations.

 

After you check the basics, send the injectors back until you get a good enough set.

 

i got 4 bad injectors from ffd and got the run around stating my issues were not from there injectors. my issues were from 2 weak and 2 bad out of 8. i didn't have the issue you are having on start up either. it didn't run great but no where near as bad as yours. i replaced mine with a new set from bitterroot diesel and have been very happy since! as FFD for the flow chart on those injectors, if they actually tested them then they should be able to include the flow chart. when i bought the FFD remanned hybrid 205/30's from FFD i also purchased the hydra tuner. they pre loaded the tunes ( i didn't ask them too) and as it turned out they loaded the wrong tunes. i found this out quickly as when i went for the first drive to begin purging the air out , i set the cruise and the cruise control light illuminated. i drive an e99 and that wasnt a feature on the e99's but apperantly the light is there. turned out they loaded tunes for a 2001 rather then an e99 but it still turned on and idled somewhat decent with a pretty bad lope. it did get better as i put some miles on it and i got the correct tunes emailed right away. i say this because there is a good possibility you have bad tunes as well as the possibility you have a few bad injectors. you still need to see the flow chart on the injectors for your knowledge. when i asked for it, they stated they do not provide them which told me they don't actually test them. i wound up making my own switch box to test the injectors by shutting them off one by one while watching mfdes.

 

dsrace. What did you do with your full force injectors after replacing them because I don’t know how they will respond to taking them back after they were installed on the truck and I can’t really afford to take a 1200$ loss.

 

They're not going to take them back unfortunately. Just ask them to build to BDP standards when you send them back.

 

Just putting this out there in case someone needs help with the same issue I had. After 2 Ford ipr and ipc sensors I had them change some tuning around trying to fix a hard shift and magically the surge and poor running was fixed. Never even crossed my mind I started to believe that I had bad ipc wiring because the truck would run great without it hooked up but a change of tuning got the job done. Everything is a learning lesson I guess.

 

ouch...be nice not every shop has a reputation of doing whats right...

to the OP forget price, consider a shop or persons reputation.. some folks still take their reputation personal, and as a result stand behind their products.

 

I ended up putting in a brand new set of Alliants over some rebuilt injectors that ran worse than the ones I took out. Stock truck, ran fine, just had a hammering injector and I wanted to quiet the engine back down. There was a noticeable half hearted engine miss on gentle acceleration, and the characteristic Powerstroke engine bark when you started it wasn't there. It would "taper up" instead of that one single romping sound as it catches and runs. I knew that the injectors were more worn out internally than the ones that I had sent back in for core. So I kicked myself and bought the new ones and never looked back after that.

 

Kenn_chan

Im not blaming or bashing anyone especially not FFD, though all the problems I’ve had there costumer service has been great offering as much help as they can, and they have been on top of trying to get my tuning revisions to me asap.

Tuning is one of those things that’s just not a one size fits all, I was just surprised that it was giving symptoms of a bad icp and the tuning fixed it