Ford 6.0L Power Stroke Diesel :: Replaced Injectors - Missing After 20 Minutes Now Won't Start
Apr 26, 2016
I have a 2003 Excursion with the 6.0 power stroke. I recently had a few codes, cylinder 2, 3, and 8 contribution/balance fault. I asked a buddy of mine, and he said I needed new injectors. I replaced them all, properly torqued everything down, and got it running. She ran for 20 minutes before it started missing again. I shut it down, and since then it hasn't started. That was two Sundays ago. Since then, I've replaced the ficm, all fuses related to the ficm and fuel pump, and even went in and checked all the connectors. Everything is in place, but it still won't run.
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I have 1 bad injector well it's missing when it's cold and two others that are "weak" I'm wondering what kind of job it would be to do by myself?
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Just replaced all hpop orings. Injectors loud after start up at idle. Guessing air in lines. How long do I need to drive before all air out of lines and everything back to normal?
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Had long start issues. Would turn over for 5 seconds - shut off- turn over for 5 seconds - shut off - third try on 4-5 seconds the low oil pressure would come up and HOP would fire injectors and start up.
Was not sure what was up, so look it to Ford. They did leak down test and found seal at the top of injector 4 was leaking. Replaced it and leak moved to other injector. Basically moving to the next weakest seal point. I told them to stop as i did not want to pay, parts, labour and shop time to replace all injectors, etc. They also said power across all injectors was good, but 3 & 7 were not contributing on cold start.
I drove it home and bought parts. New cups and seal for all 8 on fuel rail. New gasket kits for injectors. Plus 2 new injectors to replace 3 and 7.
Replaced injectors in 3 & 7 with the 2 remanufactured i bought. Replaced all cups and seals on fuel rails. So it has new injectors in 3, 4 & 7.
As for the other injectors i took the 5 of them right apart and cleaned them and re-assembled. Took about an hour per injector, took my time to get it right, just FYI. Went pretty good i thought. Seemed pretty straight forward actually.
Now no start - no high oil pressure at all. LOP comes up right away. Scanner shows no HOP no matter how long i crank it.
FICM power good, 47.5 - 48
shows FICM sync - YES
IPR sits at 14% and jumps to 84% on crank - starting, see photos below.
Scanner prior to crank
Scan during crank
Note zero IPC - PSI
Right now.... Got the valve cover off on passenger side. Cannot see oil squirting out the sides of any injectors, but line of sight is limited. Maybe need a small mirror to see in there. LOP comes up better than it has in years, but no HOP now. Before rebuild it seemed i had good HOP but low LOP.
I drove it home from Ford and into my garage, so i do not believe the HPOP crapped out sitting in the garage, so i am ruling that out as a fail, at this time.
Dummy plugs were replaced 5 years ago and o-rings looked decent.
Pulled the small plug screw at the top of the fuel rail. Cranked it until oil came out, bleeding air. then replaced the screw plug. Have not done that on drivers sideyet. Will try that tomorrow. However, think this is more than an air issue, as i have cranked it over plenty, unless i just have that much air.
Going to pull the valve cover on the Driver's side tomorrow. Then will have both covers off at same time to view all.
Noted that if i put compressed air into the screw hole on top of the fuel rail, i can hear air coming out from below the fuel rail. Nothing at the base or around injectors. Does not seem to be at the cups either.
Just wondering.... Buy applying air to those screw plug holes, is that the same as doing the air test at the sensor that pokes up through the valve cover.
With air pressure at these scew plugs on the fuel rail, should this be sealed and be air tight and hear no air leakage. Because it was not air tight on the drivers side before i closed that side up. I am curious about this.
I am assuming i still have a HOP leak. I do not think i have a failed HPOP. How to better chase a HOP leak?
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Powerstroke 6.0 no crank no start... 2004 Excursion. I cannot get any of scanners to connect to get any codes. I have the Autoenginuity Ford Package, scanguage II and another generic scanner. There is power to the diagnostic connector but there is no communication.
I have recently been having issues with rough running cold starts. Codes before this no crank event were 2285 ICP Sensor Low and 0528 fan speed sensor low and one for EGR which has been deleted. Just last weekend I had crank no start. I unplugged the ICP sensor and started and ran. I ordered a new OEM ICP sensor and pigtail and the truck sat until I received them.
Recent Work : I just replaced the ICP sensor and the pig tail. I soldered and heat shrank the wires rather than using the quick connects. I did find that after soldering the pigtail I found two wires shorted on the pigtail. Per the diagram on the 6.0 bible the a/b wires were shorted. I have corrected those. I also noticed that the top of the glow plug control connector has a broken clip. Not sure if there is a connection issue so I have tried to ensure that it is pushed in as far as it will go. I have another module somewhere I'll have to see if I can find it. Replaced glow plugs and harness about 6 months ago.
What have I done:
- Pulled access panel on FICM has 4 posts.
- FICM voltage 48v Key On.
- FICM voltage 46v cranking
Check the diagnostic connector can +/- (pins 6/14) and has resistance 122.1
I've check all the fuses and specifically:
#20 FICM
#22 Engine Control
I found one bad fuse #115 Trailer Tow Charge.
When trying to start Glow Plug light comes on but doesn't go out. The injectors are not initializing and the fuel pump doesn't seem to be running either. I have unplugged sensors ICP, EBP and FSS. Not sure what to test next. I'm considering pulling the ficm harness tomorrow to look for chaffing.
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I have been having trouble w my 04 I checked all fuses all relays all dash lights work, no buzzing on injectors when key turned on. I checked push pull plug for starter it turns over with direct to battery but still does not start. New computer on fender.
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I just finished installing a new set of injectors, standpipes and the blue spring kit on our 2005 Excursion 6.0. The truck idles and runs much better but now it takes almost two seconds of cranking to start the engine. Cold and hot are the same and the length of time between shut down and start doesn't seem to matter either.
What to check? I am planning to check the ICP tonight when I get home. Could I have air trapped some where in the system? This is my first powerstroke so I don't know if this is a possibility.
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I just replaced all 8 injectors in my 01 F550 with remans from FFD. I have noticed a constant knock at idle but truck runs great. Blowby has no pressure behind it, truck does not smoke. Does this sound like a problem unrelated to an injector?
It did not make this noise before replacing the injectors
[URL] .....
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I was driving and my truck started have lack of power, could barely get going on hills, tons of blue smoke (smelled like diesel) real rough idle. I unplugged injectors and found #5 made no difference. I replaced it today and I can't get it to start. It'll get to 2000+ psi 48v ficm, low pressure oil registers, ficm says its in sync. It will crank and blow a lot of black like its half firing or something. It has even crank to, until it tries to fire. From what I've been reading could it be the ficm? That one circuit is fried?
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I have an 06 f250 w/ 6.0. Having a no start problem. If my truck is warmed up and sits for 5 min or so and try to start it, it starts fine. If it sits longer than that , no start. But if I wait about an hour and a half, it starts right up. Why would it not start if sitting for between 10- 90 min. Starts fine cold.
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In the last 2 months I've replaced my starter and 2 new batteries. I've tested the alternator and it's fine. What more is there? I'm guessing the FICM is going to crap. If I attach a scangauge 2 to it now would it tell me if that's the problem?
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Early 2004 (IPC under turbo) 163000 miles. Injectors done last summer. Stock. Got a call that this guy died on the highway. By the time I got there (45 minutes?), it started and ran fine. He drove it for ahile, shut it down, drove it some more and it died again. I finally got it in and looked it over and test drove it. It died on me twice (Both times, I was pulled over and stopped. How lucky is that?) When it died, it showed that the Desired ICP dropped to zero just before the actual and the ICP voltage did. I wasn't watching the Regulator%. Cranking, it showed about 210 ICP and .19 ICP voltage. After it sat for maybe 10 minutes, it finally started.
Now, my question is, do I have a ICP problem or an electrical problem? My thinking is an electrical problem because to me, it doesn't seem like the oil would cool off enough in 10 minutes to allow it to become thick enough to build pressure again. I also noticed that the ICP dropped down to as low as about 590 at low idle once the oil temp was up to about 190, but it wasn't always that low - usually it was around 625ish. I have it idling right now and recording Sync now, but of course it's running fine. If my sync drops out, I need to change the Cam sensor or crank sensor, correct? If it doesn't drop out, I have a ICP problem. Does that sound right?
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I have an early 03 F250 6.0 that won't start after I replaced all 3 FICM connectors, also # 8 injector pin and connector. It has been almost impossible to start before the repair.
I checked the grounds on
Pins #1 2 3 22 they were all .5 ohms
Pin #32 was 1.0 ohms.
Pins #7 27 were 12.7v ( battery voltage)
I have double checked all pin connections and wire colors, they are in the right holes, I haven't done any cranking voltage tests, as I am alone. The FICM has 48.2 v.
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2006 6.0 king ranch 189k sct live wire Replaced 1357 injectors and when I crank truck it will crank and sputter for a brief second but will not fully start and continue cranking and doing this over and over. Tried starting for roughly 30 minutes would not budge. Tested icp and ficm both are good. Also replaced batteries, fuel filters, checked all relays and fuses still can't figure it out. Also truck is bulletproofed.
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I need to get my oil cooler replaced but that's besides the fact. I drove it on a little trip the other night ran fine. Then went to start it after i was done with what i was doing turned it over didn't start the first time. Cycled the key and cranked it again. Started up drove it back home on the high way no spitting or sputters got off the high way it started idling like crap and shaking as i accelerated but made it home. Let it sit over night and day (was at work) got home to start it and it fired up no problem but still idled funny.
Revved it a couple times and it seemed to clear up so i took it around the block. Floored it and it ran like it was suppose to then go to the other side of the block floored it again and it had no power and sounded like it was running on 4 cylinders. Pulled it back in the driveway idled weird and cleared up again went down the street and floored it ran like a scaled ape and then just died. tried cranking it over and nothing finally got it to start after holding the ignition on ran and then died again. Got it pushed home and decided to fire again after a VERY long crank and it idled for a couple minutes very horrible and died on its own and hasn't started since.
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Started my 2005 f250 powerstroke, idle about 15 min and died like I turned key off. Hooked up scan guage had no flp, fmp or syc ipr and icp was good. Checked ficm relay and fuses and all checked good. Next morning went out and it started flp, fmp, sycall good. Idled about 1 hr and died again same bad readings. Messed with relays and wiring to ficm, it started and died after 2 min. No start again, next morning still no flp, fmp. Went out again in afternoon and everything was good again, I did nothing to it from am to pm, was loading my pistol they shoot horses don't they. I have new batterys, I changed the ficm power card last summer for low fmp. When it is running everything looks and sounds good no miss.
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I was towing my camper uphill and my 03 6.0 started missing and blowing black kid smoke. Next thing I know I hear a loud pop and steam is coming from under the hood and the truck dies. I pull over and discover the degas lid is stuck on and the bottle came apart at the the seam and the truck will not start. 6.0 with 120k miles
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My A/C will blow cold for about 3 min. and then stop for 10 min......then cold again for 3 min.....then warm for 10 min.......what is going on ? It does this when on climate control and on A/C . I had a compressor go out about 1 1/2 yrs. ago due to a fan failing...the compressor tore apart... This is not acting like that though .
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I have replaced all the injector seals as well as the ball cup seals but when I crank the truck over after a few cranks I see oil bubbling up from the top of all the injectors. When looking at the injectors from the "top" side all looks well but when I use an inspection cam from down below I can see this happening. Any thoughts?
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I found some 04 injectors for a good price, will the work on my 06?
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My Excursion got 4 new injectors a couple weeks ago and when I got it back, it was running rough. My mechanic told me it was going to take about 100 miles for them to break in.
300 miles later and it is still running rough. So I opened the hood, took a look around and saw this wiring harness unplugged. Where it goes? Youtube video shows where the harness is [URL] ......
Also, my truck has been shaking violently at 50 miles per hour, unless I hit tow haul, then it is moved up to 60... I am assuming its connected some how to that wiring harness being disconnected.
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