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2006 Powerstroke, changed almost everything, including mechanics, still runs on 6.
All right guys. This is a challenging one.
About me. Super comfortable on gas engines, have repaired all phases. Total neophyte to diesels, but I have read voraciously on the subject since I have had 6.0s. (I own a company that has 4 of them.)
2006 F450 6.0.
Holed a piston in the original motor in August. Bought a low mileage long block with studs and new HG installed. Pulled the cab, swapped the motor in the first week of September. Truck hasn't run since. Installed a EGR delete kit, and new oil cooler. Proceeded to have a ton of HPO issues, turned out the Ford tech I paid cash to help me double stacked the HPOP intake o-ring...
Now that the HPO issues are sorted, the truck still clearly runs on six. I get a Cyl contribution code, either for cyl. 2 or cyl. 4. I can unplug 2 or 4 while running, and it doesn't change the miss but it does change the underhood sound. When those two injectors are plugged in, I get a distinct ding, ding, ding metallic sound. I replaced injector 2. No change. I changed injector two again, thinking perhaps I had gotten a bad one. When I started to back the injector out of the head, a jet of hot oil shot out of the back of the injector directly into my eye. Once replaced, no change, same noises.
Now I am thinking FICM issues. I have 48v across the board. My company has several 6.0 trucks, including another 06 that runs like a raped ape. I started to cannibalize it for parts. I swapped the ficm. No change. Swapped the ficm harness. No change.
I had a diag done at the stealership, and all they could tell me was the same thing my trusty ELM 327 and Torque app does. Codes for contribution on cyls 2 and 4, and a egr code. (egr deleted.)
The truck has new dummy plugs, new stand pipes, new HPOP, new IPR. Ford scan tool says there isn't a compression issue, but I have not tested it manually. At an idle, it has ~600lb of HPO, and the IPR duty cycle is 26% at an idle. It has all new filters everywhere.
At this point I am a little lost. The last things I can imagine changing are the main harness, and the pcm.
1. Oil jet to the face out of a new injector.
Is it possible the spool valve is only being driven one way, not allowing the high pressure oil out? As a result, could the ping ping ping noise from the valve cover be "water hammer" in the HPO? Is there a way to test if both solenoids on the injector are receiving the appropriate signal?
I have hundreds of hours and thousands (about ten of them) of dollars into this motor. I need it back, and need it NOW. Another 6.0, an 04, just blew the head gaskets today, and we are out of trucks to complete jobs. I am planning on buying an AutoEnginuity setup tomorrow, as well as a main engine harness. During the engine install, I noted that the harness was rubbed thru to copper in a couple places, but I repaired them on the work bench correctly using splices, solder and shrink tube. (I am a electrical contractor that specializes in instrumentation and controls.)
Anything you guys can suggest would be great. I am at my wits end on this one.
Thank You in advance.