Ford 7.3L Power Stroke (1999-2003) :: F350 Stalling When Accelerator Pedal Is Pressed And Released


Jun 6, 2017

I have an issue with my 1999 Ford F350 7.3L diesel and stalling when the accelerator pedal is pressed and released.

Background: Initially the truck would not start, and from there here are all the things that I found wrong and replaced. (keep in mind that I troubleshot all the issues and every part that was replaced was proven faulty)... Starting with the glow plugs, all but 3 were faulty and not making a connection to ground. (only one broke off in the head, but I was able to get it out with out getting anything in the cyl)..

Valve cover gasket and harnesses, this is to include replacing the connectors on the engine harness cause both sides of the connectors were broken. The ICP was leaking into the connector and breaking the connection to the PCM, so the connector was cleaned and the sensor replaced. No issues from that now.

The IPR was replaced cause the oil pressure was erratic and not stable when I had my pressure gauge hooked up testing the pressure. After that was replaced the pressure was ok, and it climbed with RPM's and fell back down like it was suppose to. I could not get the PSI up to 3000 PSI even at full RPM's, but it did not drop past 600 psi.

The fuel tank was recently replaced, and all the fuel was removed and "fresh/good" fuel was put in. The fuel bowl was cleaned out and the filter replaced. (the fuel bowl did have a lot of crap in it like rust and dirt). Fuel pressure was at 95 PSI last time I checked, which is higher than the recommended 60 to 65 PSI.

That being said the engine did start and run, but was very rough and missing. So I did all the injector o-rings. Some o-rings were starting to split, and others were not sealing like the copper washer on the injector tip. I could tell by the amount of crap in the end of the injector. ( not the tip, but where the injector contacts the injector cup. There must have been water in there or something cause that part had all kinds of crap around it)

The engine smoothed out after a couple day of running it, but it would still stall when it was cold. The block heater was replaced cause it was falling out. The oil was changed and the filter too. The CMP sensor was changed just because I know they will cause the engine not to start. I had a "known good" truck that I can swap part to and from, and I did a lot of that thus far.

Swapped the IDM, PCM, EBP sensor, MAP sensor, all relays inside the engine and in the cab. I was looking for the barometric pressure sensor, but from what I have read thus far that is a calculation in the PCM between the MAP and the EBP sensors. The diode to the PCM is good,I checked the harness for rubbing by the 42 pin connector and by the LF fender but I did not find any chaffing or rubbing on any wires. The ECPR was wired together, so I fixed it so that it is no longer that way, and the waste gate for the turbo was wired open. I took the wire off and made sure the linkage worked and it did move. I tried to lube up the valve in the turbo for back pressure, but I'm not sure if it worked or not.

I also swapped out the oil pressure sensor and the oil pressure temp sensor on the HPOP Reservoir, and blew out the EBP sensors tube. (air went straight through the tube with no restrictions.) I did a buzz test and all the coils checked out ok. I also did a contribution test and only three cylinders were identified as having some kind of issue. (but this is not enough to cause the engine to stall..) The only current codes that I have are the air intake heater, and the EF feedback not detected. Neither of which would cause the engine to stall in my opinion.

Symptoms:

When cold: The engine will start and idle just fine, but when the accelerator is pressed and held to 1000 RPM's the engine will sputter like its missing and surge up and down between 500 and 1100 RPM's. If the accelerator pedal is pressed quickly the engine speed to increase then fall down and stall. It seems as if the PCM is shutting down and starting back up. ( Like the key is turned off and then back on quickly, but the engine doesn't recover)

When warming: This issue becomes more erratic, but when hot the engine is fine. No issues, and it will drive all day long with no hesitation.

The truck has over 200K on it, but I know it will go more! It is a mannuel tranny, and is a 4X4, and I love it, I can't get ride of it just yet.

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1st I ohmed out injectors thru the 42pin harness according to tuglys sig link. My meter would only go down to a 0.4 when testing the test leads just to each other

DS injector ohms
#2 3.5
#4 3.4
#6 3.6
#8 3.6

PS injector ohms
#1 3.6
#3 3.6
#5 3.5
#7 3.6

DS glow plug ohms
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Next I checked the uvch connections which felt good, darn it, maybe a smidge of movement from the DS, but nothing halfway disconnected or anything. Hmm. I ground down the quarters to the top of his head and installed.

Next I torqued down the 4 bolts per cylinder of the rocker arms at 20 ft/lbs, all were perfect and snug

Next up, injector torque. I've read on here below 50, or 80 in/lbs depending on different threads and opinions that I would need to replace o-rings.

So I set the in/lb click torque wrench at 50 in/# and tested the wrench's click on the higher torqued rocker bolts, then checked all the injectors, all were good

Reset for 80in/lbs, tested, then hit all injectors, #6 almost budged but clicked immediately before the handle moved
Reset for 100 in/lb, tested on larger bolt, 2 injectors took a 1/8 turn;
Reset for official spec of 120 in/lb , tested wrench, all injectors took 1/3 to 1 full turn
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