Hello all, I have been trying to diagnose an issue with my 98.5 E350 7.3. I'm getting an intermittent P0278 code when I do a CCT in Forscan lite. The van starts up well, has no smoke but struggles to get up hills and get up to cruising speed.

I had the VC off and disconnected each injector one at a time while running. The engine reacted to each missing injector so it seems they are all contributing.

I also re torqued about a quarter turn each injector hold down to the factory manual specs 11 ft lbs. Rockers were already to spec.

After the advice of some members of another diesel forum I drained my fuel bowl and filled it with Sea Foam then ran it through which did make a noticeable difference in sound but none to performance.

A few years back I did the hutch mod and added a Racor filter pre pump (which I just re cleaned) and a new tank. I'm getting about 53PSI fuel pressure post bowl filter at idle then when I try to accelerate it will go down to just under 50PSI. Not sure where to look next.

Thinking maybe something went wrong with the Hutch mod or maybe I need to do a compression test on no 6?

The van has been sitting for 3 months at a time in Va. due to me needing to travel back and forth between MA and VA. When I first left I did an oil change, filled the tank and added some PS dieselKleen. It wasn't running great before I parked it so I don't think sitting is the cause.

Attached are some screenshots of PIDS from FORScan lite at idle and acceleration. Any thoughts?

 

I think you need some driving data so see what the van is doing under acceleration. I.e boost, oil pressure, and duty cycle. That will help point you towards a culprit.

 

I just uploaded some PIDS from Forscan lite in my first post. Recently tried Forscan on PC but can't seem to get the OBD to work.

 

That is a bad ramble... next time break things us for easier reading.
What I got out of it is Seafoam.. Don't. That is a gas engine thing. Alcohol is bad.
If the second screen shot is driving you need to do a CAC leak check, your map should be higher than that.

Also guessing you live up north a bit. A cold diesel does not like to go.
Do an engine off cold check of the parameters and see what you get.
Your atmospheric should be doubt 14.7 psi plus or minus a bit depending where you are.
Bad pressure sensors will cause issues.
When was the last time the Exhaust back pressure tube and sensor was cleaned?

 

Sorry, just edited the original post some.

The Seafoam was recommended by several members of another diesel forum and the label does say its ok for diesels.

There are two screen shots one at idle and the other during acceleration.

I cleaned the Exhaust back pressure tube a few years ago when I did the Hutch mod and replaced the tank. AT that time I also added a Racor filter pre pump and did the fuel bowl rebuild.

One thing that I noticed was that I can't get the nut tight on the Fuel pressure regulator line. Not sure if its supposed to be or not?

I'm not sure what you mean by CAC ?

 

Not much accel pedal in the second chart - 35% APP, and MFDES is only 33, so maybe the ICP/IPR%/MGP, etc are normal for that level. You could capture a WOT run and see if high pressure oil and boost keep up.

Recommend posting a log instead of, or in addition to, a screenshot, so we can see what the rig is doing over time.

Fuel pressure is good.

P0278 without any electrical codes like high-to-low side open, tells us possible compression issue in #6 or that fuel injector is not working mechanically.

Any blowby from the oil fill at idle? Will the oil fill cap sit upside down on it and not vibrate off?

How many miles on the rig - on these injectors?

 

The van has just under 270k, I've had it since 225k and have not replaced the injectors. I don't know if these are the originals or not.

I do know that after the tank delaminated and I replaced it and did the hutch mod etc. it ran better than ever for about a year. Before it started to develop this latest problem.

Is it possible to post a log using Forscan Lite? I haven't been able to get my OBDII to communicate with Forscan on my PC yet.

I'll take it out again today and try to get a screen shot of the PIDS in WOT.

 

Ok, so at that mileage, injectors may be starting to fail, but good to rule out other possibilities. Tell us if you have any blowby from the oil fill as a quick compression test, and then data from that WOT run would be great.

You can save a log of your run from FORScan Lite, and post it in this thread. Details on how to do this are in the FORScan Q&A thread at the top of the forum. A CSV file is preferred, but we can work with the native FORScan file as well.

 

Could have a plugged CAT if your van is equipped with one.

 

I took it out on a a more open road so I could get a more sustained open throttle and it definitely still has power just not up hills and during moderate acceleration.

I checked for blow by at the oil filler tube and there was nothing of course that would just be the driver side bank right?

I saved the CSV file and tried to load into the Pid charting tool and it didn’t load the way it’s shown in the instructions so there was no data in the chart format. I’m not sure what I did wrong? I attached some photos of what it looks like.

 

Just need to set up FORScan Lite for comma delimited data, instead of the default semicolon delimited. This information is in the FORScan Q&A thread I linked. Change that setting, and then save a CSV of your log again. It should work.

 

[QUOTE=BWST;21076116]Ok, so at that mileage, injectors may be starting to fail, but good to rule out other possibilities. Tell us if you have any blowby from the oil fill as a quick compression test, and then data from that WOT run would be great.

You can save a log of your run from FORScan Lite, and post it in this thread. Details on how to do this are in the FORScan Q&A thread at the top of the forum. A CSV file is preferred, but we can work with the native FORScan file as well.[/QUOTE

I also checked for DTC faults and got back quite a few]

 

Ok there's that P1316, so there are electrical issues with injector control after all. Run a buzz test and see what codes are stored in the IDM. FORScan Lite calls it KOEO Injector Electrical Self Test. Let's see if #6 gets flagged.



Blowby can be detected at the oil fill for either bank, since the oil drain passages in both heads lead to the common crankcase.

 

Ok figured out how to change the CSV file for IOS and will go out again and save some more PID data. I also did a buzz test and got quite a few error codes. Last Buzz test I did a few days ago came out clean. Maybe running it out on the open road while warm triggered the faults? Attached is the file with the codes.

 

Got the CSV file to work in the Pid charting tool correctly, now what is the best method to upload it into this thread? I see in the directions about using the snip tool to capture a portion of it or do I share using Excel workbook or PDF file?

By the way I’m totally aware it’s Christmas Eve so don’t sweat getting back to me until you have a chance. I thank you for getting me this far on a holiday!