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lostrider
lostrider, Ford Technician
Category: Ford
Satisfied Customers: 3075
Experience:  ASE Master Technician, Ford Senior Master Technician,Diesel certified, ASE Master, 22 yrs FORD exp.
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6.0 Powerstroke runs very rough when started cold. Wont accelerate

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6.0 Powerstroke runs very rough when started cold. Won't accelerate or shift until it has warmed up for about 15 minutes. After it warms up its great until the next cold start. By cold start I just mean sitting overnight. Doesn't matter outside temp. (currently 75 degrees outside). Only codes I got was P1400. Any suggestions.
HiCustomer this is lostrider, what is happening with your truck is the injector spool valves are sticking and causing the engine to run rough until the oil hates up and the valves start moving freely, Ford has come out with a new calibration for the PCM/FICM/TCM modules for this concern, you will need to take the truck to the dealer for the update, as far as the P1400, there might also be a problem with the EGR valve carbon up, if the truck has less than 100k miles, the repairs can be made under the diesel warrenty with a $100.00 deductible, here is a copy of the service bulletin for the recal, hope this helps.
TSB
07-5-4
  • COLD START DRIVEABILITY - WHITE SMOKE, LACKS POWER, EXHAUST ODOR, SURGES, RUNS ROUGH, OR NO START - 6.0L
Publication Date: February 27, 2007

FORD:2003-2005 Excursion
2003-2007 F-Super Duty
2004-2007 E-350, E-450

This article supersedes TSB 06-22-3 to update the Service Procedure.

ISSUE:

Some vehicles equipped with a 6.0L diesel engine may experience white smoke, lack of power, exhaust odor, surges, running rough, or no start when cold. These conditions are caused by the injector spool valve sticking internally during cold engine operation (engine oil temperature (EOT) less than 70 °F ( 21 °C)) . The concern is typically evident following a cold start after an overnight soak at ambient temperatures below 70 °F (21 °C). and may last 3-5 minutes or longer as the vehicle warms up. The concern completely disappears after driving and the EOT is greater than 150 °F (66 °C). This concern typically occurs on vehicles with greater than 15,000 miles (24,140 Km/h).

ACTION:

Diagnose and address any warm driveability issues or hard fault diagnostic trouble codes (DTCs) prior to performing this TSB. Then if cold driveability symptoms still exist use the following Service Procedure.

SERVICE PROCEDURE

This procedure includes a FICM calibration that adds inductive heating of the injector coils to locally heat the oil in the injector to normal operating temperatures very rapidly and keep it hot until normal overall engine oil temperature is achieved. This will prevent cold spool valve sticking on all injectors. Therefore, it will not be necessary to replace fuel injectors for the cold driveability symptoms listed in this TSB.

NOTE:DO NOT USE CLICK TEST OR POWER BALANCE TO IDENTIFY COLD INJECTOR PERFORMANCE ISSUES, BECAUSE THE INDUCTIVE HEATING STRATEGY IS NOT ACTIVE DURING THESE TESTS. INJECTORS WHICH DO NOT RESPOND IN CLICK TEST OR POWER BALANCE WILL RESPOND IN NORMAL RUN MODE WITH THE INDUCTIVE HEAT CALIBRATION

Inductive heat is active in Key On Engine Run (KOER) mode below 2500 RPM. It is tapered out from 131-167 °F (55-75 °C) EOT, and is fully deactivated above 185 °F (85 °C) EOT.

NOTE:IF THE VEHICLE RUNS ROUGH OR HAS A MISFIRE WHEN THE ENGINE IS AT OPERATING TEMPERATURE, DIAGNOSE THOSE CONCERNS BEFORE PROCEEDING WITH THIS TSB.

This updated calibration strategy is a greater improvement than the previous post-cycle Fuel Injector Control Module (FICM) software release that cycled the injectors after shutdown (TSB 06-22-3). This strategy will eliminate the need to post-cycle the injector spool valves, and as a result will also eliminate the need to perform the E-Series wiring modification. The strategy achieves rapid heating of the oil in the injector through inductive heating of the injector coils. The Customer Information Sheet that was included with TSB 06-22-3 is no longer necessary.

Customers who receive this new calibration after previously having received the post-cycle calibration (described in 06-22-3) will notice the buzzing noise at shutdown has been eliminated. This is normal, as the post-cycle is no longer needed with inductive heating. Additionally, for E-Series there is no need to remove wiring modifications that were previously performed per TSB 06-22-3. Unmodified E-Series vehicles will NOT need the wiring modification with this calibration.

  1. Using Module Reprogramming: FICM menu in IDS, reprogram the FICM to the latest calibration using IDS release 47.8 and higher or 48.2 and higher. This new calibration is not included in the VCM 2007.3 DVD. Calibration files may also be obtained at www.motorcraft.com.
  2. If the customer previously had the Post Cycle calibration, notify them they will no longer hear the injector cycling after engine shutdown.

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

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