I have a 2004 F-250 that has started to sputter some when the temperature reaches 40 degrees. Its not a dead miss, just a sputter for maybe 10 seconds. Last winter I noticed that when I turned the key on to cycle the glow plugs and injectors, the sound started to change. Previously I could here the fuel pump running, the glow plug relay would kick on and off and I could here a loud buzzing, arcing sound which I attributed to the injectors cycling. The buzzing, arcing sound started to get weaker over time until it was totally gone. As the sound weakened, the sputtering started during cold weather starts. I checked the FICM voltage, it stays around 47.8 to 47.9 volts and it has relatively new Interstate batteries. It started around the same time that I replaced the IPR valve. I can't remember if I disconnected both batteries when I replaced the valve, but I think I did. I've re-checked connections at the FICM. Any suggestions?

 

Injector sticking maybe, how many miles on the truck? Had the EGR out lately?

 

140,000 miles. The EGR is disconnected. Its not a dead miss just a rough idle for 5-10 seconds. The think that puzzles me is that I don't hear the buzzing anymore. I'm going to retest the FICM. I was doing the test by myself and did not have any way to load test it.