Greetings all, been lurking here since I picked up my '02 F-350 7.3 w/ 130k (currently 136k). Learned alot here.

2 days ago, drove around town, just fine. This morning, started the truck just like normal and made it 1/4 mile down the road before check engine light comes on, sputters, and dies, as if out of fuel.

Replaced cam sensor, No oil in ICP, checked ICP by removing pigtail, still no start. Its getting fuel as I have white smoke puffing out as I crank and the oil pressure gauge on the dash shows normal. No check engine light, WTS light lights as normal. Oil good, fuel 1/2ish tank.

Thinking IPR, but couldn't tell if a bad IPR would cause sputtering and stalling while driving. From what I saw it just caused a no start condition??

 

FORScan or FORScan Lite and the OBD II reader they tell you to use.
Pull all codes and record them, clear all codes, pull all codes again and what do you have both times.
Run every test FORScan has and let us know what happened.

Did you get all your engine sensors and control items from the FORD or International counter guy, RiffRaff Diesel, or CNC Fab? Good.
Or did you use the internet and order from Cramazon or Fleaybay or one of the other internet places possibly the corner store to get your counterfeit Motorcraft china part? Bad.. Do again as the above line provided.

Do you have at least 1/4 tank of fuel? See Hutch/ Harpoon Mod.
Do you have oil on the hashmarks on the dip stick of proper type and intervals?
Did you prove every engine connection and pigtail? Did you strip the pigtail on the CPS all the way up and around the top of the water pump to the EBP sensor as well as all sensors and control items to prove the wires are physically and visually intact?
Did you prove your electrical system is in perfect condition? See the attachment and do everything.
Is the Tin Nut on the IPR snug?

 

IPR doesn't sound likely based on the smoke. If you weren't getting hpo then the injectors wouldn't fire and nothing to make smoke. As stated Forscan and a compatible dongle to check codes and get a look at some sensors data is the smart move. A fuel pressure test is never a bad idea and the fact there isn't a SES light suggests it could be a fuel problem. Do you hear the pump cycle when you turn the key to ON?

 

Thanks for the suggestions!

- All sensors I have replaced have been from RiffRaff.

Fuel
- has 1/2 tank (ish)
- can hear fuel pump
- drained fuel bowl and it filled back up

Oil
- was just below top of hashmarks
- added 1 qt to get to top
-T6 5W-40 oil change 1600 miles ago.

Electrical
- batteries & battery harness new (2000 miles)
- starter new (2000 miles)

Got Forscan on a laptop and picked up an OBDII adapter. Picked up these codes:

IC: B1352 // U1950 // U1262
PCM: P1280 // P0475 // P1316

Wiped the codes and it still picked up:
IC: U1262
PCM: P0475

Then ran self tests that I could without a warm engine and running engine

**KEOE Injector Electrical Self Test**

Code: P1294 - Injector High Side Open - Bank 2
Module: Powertrain Control Module
Diagnostic Trouble Code details
Injector High Side Open - Bank 2
This DTC may be caused by :
Open circuit.
Possible causes are:
Harness wiring
Fuel Injector
DIDM
Inspect connectors for signs of damage, water ingress, corrosion, etc.

**KEOE Output State Self Test**
Code: P0475 - Exhaust pressure control valve malfunction
Module: Powertrain Control Module
Diagnostic Trouble Code details
Exhaust pressure control valve malfunction
This DTC may be caused by :
Open circuit.
Short circuit
Possible causes are:
Harness wiring
Exhaust back Pressure Regulator
PCM
Inspect connectors for signs of damage, water ingress, corrosion, etc.


So it looks like the common theme is P0475 - Exhaust pressure control valve malfunction. or the PCM.... Though I haven't seen anything that the EBPV would cause the truck to sputter and die. I've seen that it has a no start condition?

 

P0475 is a nothing code. Has your EBPV been deleted or disabled, most people do. They are way more trouble and potential trouble than they are ever worth. Unless you've recently checked and cleared codes we have no way of knowing how old those codes might be. The SOP is to record the codes, then clear them and see what comes back. If nothing pops right away an extended crank time of 30 seconds should trigger a code for hopefully what the problem is.

 

I don't believe its been deleted/disabled, though not sure. Only had the truck for 9 months. It did pass CO Emissions back in the fall.

First check of the codes was IC: B1352 // U1950 // U1262 and PCM: P1280 // P0475 // P1316

I cleared the codes a couple times and these 2 came back: IC: U1262 / PCM: P0475

When cranking, I'm now getting grey smoke vs the white smoke. It sounds like it wants to start, but it won't.

 

Visibly check the bottom of the 42 pin connector for any chaffing. It’s in the drivers side of the engine, attached to the valve cover. It takes a 10mm to undo. I had an issue with my 02 where it would die randomly and would only crank. I took it to a mechanic and he tried everything and couldn’t get it to die, including wiggling that connector and harness. When I removed it I found a barely visible copper wire and that was the cause. Fixed it and have never had another issue.

 

Checked both sides of the 42 pin connecto (and all other connections). All look good, no fraying/chaffing.

 

Did you check Fuel Bowl Heater fuse... I think #30 under hood.

 

If the WTS light goes on it is NOT the Fuel Bowl Heater ...Is there anyway you monitor the IPR with a real scan tool that can measure Live Data to see if you are getting at least 500 psi while cranking ? If No then it could be an Injector O-ring issue or an IPR Issue .....Can you check the Tiny Tin Nut on the Back of the IPR so see if it is loose ? Also Inspect the IPR Pigtail ...could be rub -out ...Final point is to see if you have at least 50 psi Fuel Pressure ..you need to put a guage on the shreader valve or Tee into the supply line at the Bowl to see if you have pressure ..also check fuel pump relay if it works ...good luck

 

What Schrader valve? The fuel bowl drain valve works as a temporary fuel pressure test port though..

 

Take it easy .... my 95 has a shreader Valve ...My E99 has a electronic fuel pressure guage ...my point was to see If the OP could monitor fuel pressure under Load or Not ...That's it

 

Other than that I would remove the VC's and Inspect the Injector wiring and the VC gaskets for Burnout ...BUT when that happened to me 3 times so far it was always the IDM.....When it ran like crap it was the harnesses and the pigtail on one side .... Just sayin
https://k-mansparts.com/items/trucks...items/list.htm .... OEM parts are your friend

 

Later model 7.3s don’t have a Schrader valve, I think that’s all they eye getting at.

The best point to take pressure is from the lower port on the fuel bowl, this is the pressure after the fuel filter. It is a bit of a pain to get to.

https://www.ford-trucks.com/forums/1...est-ports.html

 

I know that ... the sender for my E99 gauge is on that port post filter as it should be ...thanks for posting the link to the older thread by the way .... I did not Install that myself the previous owner did those mods and others.... the truck was a long distance Trailer hauler before I got it ...so it has all those extras ... Now It's just a Construction Truck that can Tow / Haul alot ... more like a 350 /450 ....It puts newer truck to shame when it comes to that ....