The Check Engine Light may come on with codes in engine computer memory for P0401, P0402, P0404, and P1335. In addition white or black smoke will be emitted from the tailpipe and the engine will feel down on power. This is most commonly caused by build up of black sludge and other solid deposits in the Exhaust Gas Recirculation (EGR) System (EGR Valve, EGR Cooler, Exhaust Back Pressure (EBP) Sensor, and EBP tube), intake manifold, turbocharger and the EGR throttle plate. Regularly adding a cetane booster to the fuel will aid in a more complete combustion and the engine oil should be replaced at the proper intervals to avoid sludge build up. Installing an EGR baffle kit also helps to prevent future EGR valve contamination.
Problems for specific Ford E-350 years:
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Newest reported Ford E-350 problems
Appropriate cooling system maintenance is very important for this engine. Coolant should be inspected for nitrite levels at each service, and use of an additive, or replacement of coolant, should be done as needed. Deteriorated coolant can lead to EGR cooler and / or engine oil cooler failure. Failure of either can cause coolant loss and overheating, prolonged overheating can cause head gasket failure. White smoke may also be emitted from the tailpipe from the burning of coolant. The cooling system should be thoroughly inspected, and replace the EGR cooler and components as needed. With extended overheating, the head gaskets should be inspected for damage. If the cooling system is especially contaminated with oil, flushing agents and a degreaser like Simple Green may be needed to effectively flush the contaminants.
Damage to the fan clutch wire harness and / or erratic fan clutch operation can cause the engine cooling to not turn on. A new fan clutch assembly will be needed to fix this problem.
Engine oil leaks from the high pressure oil pump area can be caused by leaking high pressure oil pump O rings and / or outlet fittings. The high pressure oil pump will need to be resealed if it is the source of the leak.
Engine oil may leak externally from the cylinder head gasket. The gaskets were contaminated with metal debris from the factory – between the block and gasket and/or the head and gasket. To correct, the head gasket must be replaced and the mating surfaces on the cylinder head and block need to be inspected for chips or damage. In some cases the cylinder head will not be repairable and will need replacement.
If engine idle rolls up and down, and diagnosis rules out Idle Air Control (IAC) valve issues and vacuum leaks, the Programmable Speedometer/Odometer Module (PSOM) can be at fault electronically. The instrument cluster will need to be replaced, the PSOM is inside the cluster.
Sludge build up on the throttle plate and/or idle air control valve can cause a poor engine idle, stalling, and/or hesitation – especially when the engine is still cold. The correction is to install a new idle air control valve spacer kit to prevent the sludge build up.