early '04 no power, no start when hot after rebuild - Ford Powerstroke Diesel Forum
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Old 01-08-2012, 12:19 PM
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early '04 no power, no start when hot after rebuild

I just did the bullet proof and re-ringed and new bearings, APR studs, head gaskets, oil cooler, egr deleat all gaskets and seals,...got the engine back in and runs great sitting there, nice spool and sounds strong, but no power when going up a hill, shut the truck off when it's hot it wont start, wait until it cools down and fires right up. Before all these updates and fixes I pucked the oil cooler...oil in coolant blew all over driveway...but that day it blew it had low power, I just figered it was the oil cooler but now, I don't know, I did not change IPC, IPR or HPOP...it does have all new seals and gaskets throught the whole engine and one new injector.. I am lost at this point and don't have a scan tool, read it could be a sensor, but not sure where to start....any help would be great!
Thanks,
Bill
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Old 01-08-2012, 02:46 PM
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first place to start is icp sensor. u need something like a scangauge2 to montior hp oil pressure. it could also be the ipr, hpop, or the injecotr orings. my guess is icp or ipr. but u need gauges to tell.
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Old 01-09-2012, 03:03 PM
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Why was all this work done. How did it run before the work. My first thought is the injector that was replaced. common mistake- not removing the old copper tip washer from the injector bore then in turn installing another washer with the new injector. this allows combustion gases into the fuel system killing fuel pressure. without a scan tool or a fuel pressure gauge, your going in blind. Maybe first try the bubble test.
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Old 01-09-2012, 03:11 PM
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I would at least start with checking codes. Hate to say it but without a scan tool this is just going to be a guessing game. If no codes are logged then you might want to check fuel pressure.

I would use a scan tool to watch ICP desired, ICP actual, and MAP.

6.0's can be tricky to diagnose and you can wind up throwing a bunch of parts at them. Either get ahold of a scan tool or have someone check it out for you.
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Old 01-10-2012, 06:07 AM
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I replaced all the copper tips and know for sure they were'nt dubbled up. The truck ran good until the day the cooler let loose, that is why I decided to pull and rebuild 179,000on it. That day it had low power also and a no start when hot...I am leaning to a HPOP now, they only thing I didn't change, $600 I was hoping it was good, but might bit me in the *** now. A guy I talked to from here says he is willing to check it out with his scan tool, the Snap-On one I used didnt say much for codes just the eger which i deleated and it said low ICP, someone one here said the long start to get it cranked back up after rebuild could through a low ICP code...I am thinking ICP, IPR HPOP, or HPOP leak, but what one is the question?
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Old 01-10-2012, 07:48 AM
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Did that low ICP code say "low ICP" or "low icp during cranking" I know mine has a separate code for each
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Old 01-11-2012, 04:43 AM
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cant remember what the icp said....I thinmk I am buying a scanner....the Auto Enginuity seems to be the best bang from what I am reading....any input? I plan on keeping the truck for awhile so probably a smart move and better then buying parts I dont need.
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Old 01-12-2012, 01:56 PM
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The Ford enhanced coverage from AE is great. I use it on a daily basis for most of my diagnostics. Your not going to find anything out there that will do as much for the same price. If you plan on keeping the truck and doing your own work on it then a scan tool is going to be a necessity.
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Old 01-12-2012, 02:40 PM
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I was lookin at the Auto Enginuity at one point. I agree with you, for the money it looks almost as good as anything the dealer would have. I wonder if it will do a balance test. I know you said the truck is an early 04, but this is just throwin ideas out there. 2004.5 started with the dummy plugs. Do your hi pressure rails under the valve covers have dummy plugs? Leaks at the dummy plug seal or stand pipes seals can cause hard hot starts and I would imagine poor power if it cant build High pressure oil
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Old 01-12-2012, 02:46 PM
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Quote:
Originally Posted by michaelaiman View Post
I was lookin at the Auto Enginuity at one point. I agree with you, for the money it looks almost as good as anything the dealer would have. I wonder if it will do a balance test. I know you said the truck is an early 04, but this is just throwin ideas out there. 2004.5 started with the dummy plugs. Do your hi pressure rails under the valve covers have dummy plugs? Leaks at the dummy plug seal or stand pipes seals can cause hard hot starts and I would imagine poor power if it cant build High pressure oil
It was actually about 10/03 that they changed the high pressure oil rails to the style with the high pressure oil rail standpipes and dummy plugs.

AE will not do an automated cylinder balance test, but will let you manually cut out one cylinder at a time. I use this to isolate weak cylinders/injectors. It's a little tricky to use at first and is not the most user friendly software out there but definitely the best bang for the buck. You can also actuate the VGT solenoid to check the turbo, and control the fan clutch with it, along with many other tests.

In my opinion it's one of the best investments anyone with a 6.0 can make, if you plan on trying to do your own diagnostics and repairs.
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hpop, ipc, ipr, no power, wont start when hot

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