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post #1 of 30 Old 09-25-2012, 03:25 PM Thread Starter
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Completely at a loss.

Was waiting for a train today and suddenly the truck started to miss horribly, black smoke pouring out of the exhaust. The miss got worse and worse until the truck died. I had to restart the truck to get it out of the roadway and it didn't have enough power to move itself hardly.

The deltas are usually 5-8* max. Fuel pressure is 55psi, FICM voltage is 48.5-49v checked with my meter. HPOP pressure is around 800psi unless I"m misunderstanding something thats more than enough.

Now the truck won't start, zero smoke out of the exhaust it doesn't even sound like it's injecting fuel. I would say it was the ficm but the voltage reads good. I unplugged the ICP just to try and see if it was bad and the truck still turns and turns with no catch.

Any ideas fellas? I hope that I have enough information above. Oh running motorcraft filters and caps and delo 5w40 synthetic oil changed about 800 miles ago.


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Last edited by dowmace; 09-30-2012 at 02:35 PM.
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post #2 of 30 Old 09-25-2012, 04:06 PM Thread Starter
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Just checked and when cranking I get lots of air in the fuel filter housing. I believe that means the o-rings on the injectors are bad correct?


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post #3 of 30 Old 09-25-2012, 08:43 PM
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Just checked and when cranking I get lots of air in the fuel filter housing. I believe that means the o-rings on the injectors are bad correct?
It typically means an injector(s) are loose, or somehow the copper gasket(s) are shot.

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Unfortunately had to Sell my ......2004 KR CC SWB FX4 - Edge insight cts, blue spring upgrade, updated HFCM drain plug, XDP coolant filter, CAT EC-1 rated coolant, Custom Diesel EGR delete, CAT delete, Rotella T6

SEE MY OIL COOLER REPLACEMENT AND EGR DELETE -
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post #4 of 30 Old 09-29-2012, 09:22 AM Thread Starter
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Pretty sure I found the problem.

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post #5 of 30 Old 09-29-2012, 10:28 AM
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Pretty sure I found the problem.

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Yea, was it loose?

Sent from my phone that somebody didn't help me get.

Unfortunately had to Sell my ......2004 KR CC SWB FX4 - Edge insight cts, blue spring upgrade, updated HFCM drain plug, XDP coolant filter, CAT EC-1 rated coolant, Custom Diesel EGR delete, CAT delete, Rotella T6

SEE MY OIL COOLER REPLACEMENT AND EGR DELETE -
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post #6 of 30 Old 09-30-2012, 02:34 PM Thread Starter
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the injector didn't seem loose. But now we have a bigger problem.

I put new orings on all the injectors and replaced the number 7 injector which is the one in the picture. Put it all back together and now I have 0 hpop pressure. I put new oil, and new fuel filters in it. cranks and cranks and I get zero pressure out of the sensor so I unplugged it to put the truck in default mode but still nothing.

Can I assume the hpop is dead? If thats the truth I'm just going to light the truck on fire and watch it burn. I've already put more money into this truck than what it is worth on kbb.

It's funny I had a 95 chevy with the 6.5 in it and it ran forever this piece of **** won't run for more than a week without needing 1000+ in repairs.


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post #7 of 30 Old 09-30-2012, 02:42 PM
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It could just be air in the rails. When I put mine back together, I filled the hpop resivor with oil and pulled the highest plugs out of the rails and filled them with oil before tryin to start.
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post #8 of 30 Old 09-30-2012, 02:47 PM
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Did you inspect your dummy plug and standpipe orings? And the torque on the standpipe is 60 ft/lb I believe.

Sent from my phone that somebody didn't help me get.

Unfortunately had to Sell my ......2004 KR CC SWB FX4 - Edge insight cts, blue spring upgrade, updated HFCM drain plug, XDP coolant filter, CAT EC-1 rated coolant, Custom Diesel EGR delete, CAT delete, Rotella T6

SEE MY OIL COOLER REPLACEMENT AND EGR DELETE -
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post #9 of 30 Old 09-30-2012, 03:08 PM Thread Starter
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Orings on the standpipes and dummy plug looked good. I torqued to 65ft/lb I thought it was around 60ft lbs but couldn't remember. Surely 5lbs of overtorque didn't cause the problem I wouldn't think.

I just put both batteries on the charger I'm afraid if I keep trying I'm going to end up killing the ficm with low voltage. I'm praying/hoping that I'm just not getting enough rpm out of the starter to make pressure is that possible?

The gauge on the dash moves so I know my low pressure oil is good.


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post #10 of 30 Old 09-30-2012, 03:20 PM
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Pull the icp sensor off the valve cover and spin it over, that will let you know if its oiling and get the air out. Be carful it has the potential of making a hell of a mess!

Did you fill the oil at the oil fill tube? Try pulling the filter and pouring oil in the housing to make sure the hpop resivor is full
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