04 6.0L can't figure out engine issue - Ford Powerstroke Diesel Forum
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Old 12-08-2011, 09:45 PM
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04 6.0L can't figure out engine issue

I read this forum pretty often but never post. Long story short, is I have seen on here and read several people with some of the symptoms my truck is having, but none are quite the same.
2004 truck (03 Engine) 6.0L PSD, Stick shift, 160k miles, All brand new injectors about 20k miles ago. I've been driving this truck since Nov. 04 with very little trouble. Daily driver and I put about 30k miles/year on the last couple of years.
This is what I can tell you. Left for work to get fuel and turned my truck off at the pump, which I normally do not do..but my E brake is worn out and it rolls sometimes. Filled up and started it, but it was different sounding instantly..barely started and sounded very muffled like under the hood with little to no throttle response. It sounded like a compact tractor seriously(think 3 cyl. kabota). It still does and I have not driven it since then which was 3 weeks ago. I limped it back home and drove my other truck to work. So after reading several possible things I checked all that I knew how to. The FICM is getting full voltage..a little over 48V, I pulled the EGR valve after much work and ended up breaking it as it was totally stuck in there..had to put a brand new one in. The new valve did absolutely nothing to fix it. Batteries are probably 2 years old, so I dont think that would do anything. The injectors are new. I returned the computer to stock..no difference. Just everything about it sounds funny. Starting it is hard all together now..almost like the starter is keeping it running sometimes until it will run on it own at super low RPM..like 250 rpm. Turbo sounds like it is spooling, but honestly the overall sound of the engine and the strange throttle response has me freaking puzzled to say the least.
The truck does not have EGR delete or anything, but I have never had issues with it. It is straight piped, turbo back. Running bully dog stuff on this truck for over 4 years. My other truck I use SCT stuff.
I need help here if anyone has some legit suggestions. I'm not a diesel mechanic, but a pretty mechanical guy and been driving powerstrokes since 1994. I'm just stumped. HPOP maybe?? Does blow some white smoke, but it's been cold here and both times I've started it have been at dark, so it's hard to tell for sure.
The codes it kicked were the KAM one and then one that shows up if you unhook your batteries(which I did), cant remember the numbers. P1000 and P0603 maybe?

Fire away I would appreciate the help.
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Old 12-08-2011, 10:48 PM
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For a good Internet diagnosis we usually need some hard data, but you left a few clues to get started.

Why are the injectors new? What problems did you have with the old ones? Did you test fuel pressure when they were replaced? Low fuel pressure is a MAJOR cause of injector failure. ( Might be time for fuel pressure regulator upgrade)

Do you have anyway to get ICP and IPR data? What about map and exhaust back pressure. Can you let it run a few min and pull some solid codes again. Does it run the same cold as hot? Any smoke if so what color? What else can you tell us about the service and maint history. Does it have a motorcraft oil filter in it ( yes it matters)? I have a t-shooting guide in my signature, but I am not so sure it will help you on this problem.

Main suspects, given the info you have provided, in order of probability :

Low fuel Pressure, clogged fuel filters

A slug of bad fuel


If you have the throttle blade on you air inlet elbow make sure it's not stuck closed.

( You don't need this and can remove it entirely)

Low ICP


Tube for exhaust back pressure sensor plugged up. ( not sure if your year has one)


Air Filter plugged up


Not sure if you have a MAP sensor or not , if you do check the hose going to it.

Last edited by HAM_RADIO_MAN; 12-08-2011 at 10:54 PM.
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Old 12-09-2011, 11:13 AM
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Okay, I feel a little over my head already with some of the stuff you are talking about. Something I had forgotten to mention was I replace both fuel filters also..no change. I didn't change the injectors myself. There is a local guy around here that does some serious mechanic work in his full on shop at his house, plus he works his day job as a city employee shop mechanic. He did all the work, so I cannot say for sure what he did and didn't do. He's pretty well respected and I didn't question his opinions. The original injectors were going bad for quite a while, I just drove it as long as I could to make it through last winter. I had the dealer check them first, then ended up going to his private guy for a better deal. He said he does not put in remanufactured injectors..he just doesn't like to do that. So he put all new ones..Alliance I think?? Prior to the new ones, it was just running rough, bucking, jerking, missing on occasion. Once I got it back from him, everything was fantastic, has run strong ever since, until now. I have not data on the ICP and IPR.
As far as general maint work I change oil every 5,000 miles as I drive a ton and dont care to be changing oil every 3 weeks or whatever. I have a good relationship with a local ford dealership and they do all my stuff. At 100k, I had all the radiator and tranny serviced, etc. Normal brake work etc.. I do have motorcraft oil filters and fuel filters. As far as I can tell it runs exactly the same cold as hot..only that it's a bit easier to start hot. I do not know about the fuel pressure. I assume I need certain tools to get that info, which I probably don't have. I will try pulling the codes again and see what I come up with. Seems to me like it would be something simple since there were no prior signals..was just like flipping a switch, fine one minute then a totally different truck the next. frustrating.
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Old 12-20-2011, 09:22 PM
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Talking Problem solved!!

So, it WAS the FICM afer all. My mechanic says even though it was getting full voltage, it still had an electrical fault somehow. He ended up trying 3 different FICM units just trying to pattern the problem.. Mine worked periodically, but was bad in the end. Put in a new one, reprogrammed it and it worked. It also had a bad connection on the main plug that goes into the back of the FICM. It could be that the bad connection from heat and vibration caused the problem from the get go, not sure though.
$1,100 later it's fixed. bitter sweet I guess. We did not replace the the wiring harness that has the bad plug ends. We improvised. That electrical harnes is $700 new from ford, or I could have tried to find it at a salvage yard...didn't have time really to do all that nor did I want to spend the $$ on a new one.


Anyway, I just wanted to update the situation.

Thanks!
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