No start after Bulletproof - Ford Powerstroke Diesel Forum
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post #1 of 38 Old 08-03-2014, 08:38 AM Thread Starter
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No start after Bulletproof

Background: Truck is a 2004 6.0/5R110,
I am very mechanical but not certified in anything. I have worked on Mustangs, F150's, etc. This was my first diesel teardown. Member of F150 forum with over 1000 posts, so not a complete noob to mechanical and discussion. Thanks for any advice up front. The truck ran fine before I tore into it, It just had a 20 Delta EOT/ECT..so I figured go big because I don't want to go back in there. I replaced almost everything. I am using the EDGE CTS evolution to get the numbers below.

I installed the updated Ford oil cooler and screen, HG's, ARP's, updated stand pipe/dummy's, updated turbo feed and drain tubes, motorcraft glow plugs with new harnesses, IPR coolant filter, o-ring the injectors(just the two on outside), new gaskets on every surface, etc, etc
I got the truck started after everything was complete but it took some ether after cranking for 20 mins. Crank for 20-30 seconds then wait a few minutes and try again. But it ran/idled great for first startup after the bulletproofing was complete. Let it idle for two hours, shut it off, went about my business and came back two hours later and it started right up..nice and crisp no lag in cranking just popped right off. I go out the next morning and it wont go. Its cranking like the other day but a shot of ether kicked it off? Let it run a while shut it off then I go out yesterday morning and it just cranks. I hate using that starting fluid but even that wouldn't make it run. It would but you had to keep giving it a squirt, not wanting to damage anything, I stopped. So now it wont START!?
My DTC's are P0403, P0405, P0683, and P1000
ICP cranking voltage is 1.3-1.5
ICP pressure when cranking is 995-1045ish(was hard to watch)
FICM is at 48.0
Batteries at cranking are 11.8-12.1
Tried to disconnect the ICP connector and then put back on
oil pressure gauge isn't moving after being cranked over..or is that just 05+?

Sorry its so long just wanted to give all the details. Thanks again fellas.

Last edited by Fordmotorsport; 08-03-2014 at 08:41 AM. Reason: new info
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post #2 of 38 Old 08-03-2014, 09:52 AM
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did you replace the copper washers on the bottoms of the injectors?

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post #3 of 38 Old 08-03-2014, 03:55 PM
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Following up to what Matt said, did you confirm that the old copper washers came out when you pulled the injectors?

Oh and you put in another crappy Ford oil cooler. How do you figure you "bulletproofed" it?

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Engine Mods:
Fluidampr
CCV Reroute (Reinstated)
4" MBRP Exhaust
MTW Stage 1 Turbo
Bulletproof 53V FICM
BulletProof EGR Cooler
BulletProof Water Pump
Riff Raff Intercooler Boots
Gogo Diesel Direct Drive Solenoid
BulletProof All-Aluminum Radiator
BulletProof All-Aluminum Intercooler
BulletProof Oil Cooler System w/ Bypass Filter
SCT w/ Custom Tunes (TSD, DJ's, Innovative, Gearhead, QuickTricks)

Exterior Mods:
Bilstein 5100 Shocks
Icon Adjustable Trac Bar
Firestone RideRite Air Bags
BDS Dual Steering Stabilizer
Aluminum Finned Differential Cover
Reese 16k Manual Slider 5th Wheel Hitch
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post #4 of 38 Old 08-03-2014, 04:24 PM
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Quote:
Originally Posted by Evil Eye View Post
Following up to what Matt said, did you confirm that the old copper washers came out when you pulled the injectors?

Good point.

Oh and you put in another crappy Ford oil cooler. How do you figure you "bulletproofed" it?
He will be ok as long as he got rid of the Ford Gold crappy coolant.


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post #5 of 38 Old 08-04-2014, 05:01 AM Thread Starter
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Quote:
Originally Posted by sinner6.0L View Post
did you replace the copper washers on the bottoms of the injectors?
No, I left those alone, didn't change them out.

Quote:
Originally Posted by GoFastPadre View Post
He will be ok as long as he got rid of the Ford Gold crappy coolant.
Yes, I am using the Fleetrite ELC. Forgot to mention I also installed the RCD EGR delete. I thought I read somewhere that 04 model can be left alone but 05+ has to be plugged in or deleted in the tune? Correct or no?
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post #6 of 38 Old 08-04-2014, 02:39 PM Thread Starter
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BUMP, anyone have any ideas? daily driver need to get this going.
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post #7 of 38 Old 08-04-2014, 05:09 PM Thread Starter
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Trying to research and I tried to unplug the ICP on the passenger valve cover. Question: If I unplug the ICP does this interrupt the IPR signal or could a clogged screen still cause a no start even with the ICP unplugged? Hope that makes sense.
Also, I wqas reading about FICM sync to PCM, on my CTS it read 1? Thoughts goo or bad? Thanks.
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post #8 of 38 Old 08-04-2014, 05:52 PM
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Quote:
Originally Posted by GoFastPadre View Post
He will be ok as long as he got rid of the Ford Gold crappy coolant.
That has not been proven. In fact, people have clogged up factory coolers running ELC.

Shawn Carlson

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Engine Mods:
Fluidampr
CCV Reroute (Reinstated)
4" MBRP Exhaust
MTW Stage 1 Turbo
Bulletproof 53V FICM
BulletProof EGR Cooler
BulletProof Water Pump
Riff Raff Intercooler Boots
Gogo Diesel Direct Drive Solenoid
BulletProof All-Aluminum Radiator
BulletProof All-Aluminum Intercooler
BulletProof Oil Cooler System w/ Bypass Filter
SCT w/ Custom Tunes (TSD, DJ's, Innovative, Gearhead, QuickTricks)

Exterior Mods:
Bilstein 5100 Shocks
Icon Adjustable Trac Bar
Firestone RideRite Air Bags
BDS Dual Steering Stabilizer
Aluminum Finned Differential Cover
Reese 16k Manual Slider 5th Wheel Hitch
Icon 2.5" Leveling Kit w/ F-350 rear blocks
20" BMF Novakanes wrapped in 33" Nitto Terra Grapplers
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post #9 of 38 Old 08-04-2014, 05:56 PM
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Quote:
Originally Posted by Fordmotorsport View Post
Trying to research and I tried to unplug the ICP on the passenger valve cover. Question: If I unplug the ICP does this interrupt the IPR signal or could a clogged screen still cause a no start even with the ICP unplugged? Hope that makes sense.
Also, I wqas reading about FICM sync to PCM, on my CTS it read 1? Thoughts goo or bad? Thanks.
Pulling the plug on the ICP fools the computer into thinking it has more pressure than it does and if the ICP is bad will allow the truck to start. Otherwise, it's something else. Based on your readings in your first post, it doesn't seem likely that it's a high pressure oil problem. FICM sync reading 1 is good.

P0683 is a glow plug to PCM communication error. P1000 is bogus and the other 2 are related to EGR flow (since you have a delete are to be expected). Are you sure you didn't forget to plug in a wiring harness somewhere?

Shawn Carlson

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2008 F350, CCLB, 6.4 PSD (Brad-the wife's truck is black)



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Engine Mods:
Fluidampr
CCV Reroute (Reinstated)
4" MBRP Exhaust
MTW Stage 1 Turbo
Bulletproof 53V FICM
BulletProof EGR Cooler
BulletProof Water Pump
Riff Raff Intercooler Boots
Gogo Diesel Direct Drive Solenoid
BulletProof All-Aluminum Radiator
BulletProof All-Aluminum Intercooler
BulletProof Oil Cooler System w/ Bypass Filter
SCT w/ Custom Tunes (TSD, DJ's, Innovative, Gearhead, QuickTricks)

Exterior Mods:
Bilstein 5100 Shocks
Icon Adjustable Trac Bar
Firestone RideRite Air Bags
BDS Dual Steering Stabilizer
Aluminum Finned Differential Cover
Reese 16k Manual Slider 5th Wheel Hitch
Icon 2.5" Leveling Kit w/ F-350 rear blocks
20" BMF Novakanes wrapped in 33" Nitto Terra Grapplers
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post #10 of 38 Old 08-04-2014, 05:59 PM
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If you unplug the ICP the PCM sends a false signal to the FICM that the oil pressure is good enough to "fire" the injectors. If the true pressure is too low (what ever reason), the engine will not start. If the IPR is stuck open, the pressure will be too low for a injection sequence and start.

"1" means sync. That is usually a good thing.

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KC-68 Stage 3 Turbo,
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