6.0L No start hot

[Danodb]

Thank you in advance for all reading this. This truck was
brought to us with the complaint of no start hot. It was low
on engine oil and it was dirty. We changed oil and filter,
problem persisted. DTC p2291 (ICP too low engine cranking),
Pids 350-375 psi and icp .6-.67 volts. We cut and examined
the old oil filter and found scattered metal flakes on the
media, not bad but some. Magnet on oil plug was "furry" First checked for hi press. oil leaks with valve covers removed, with two hundred psi of
nitrogen press. and IPR commanded closed, we heard a leak on
RH side,replaced stand pipe orings on both sides and
retested, no leaks heard after retest. reassembled and drove
until hot, problem still persisted. We removed Injector Pres.
Reg. and it had a little debris, so we thought we were on the
right track We suspected Hi Pres. oil pump failure at this
point because watching the pid's while cranking engine hot,
had 350-375 psi and icp .6-.67 volts still and the metal
found in the filter. If it cools off for 30 mins. will start
with 15 sec. of cranking, after an hour or so,starts right
up. But it has to hit that .8v point on the ICP volts pid. We
replaced the Hi Pres oil pump, It starts (cold) and runs much
smoother and quieter but same symptom. No start hot. Pres and voltage on
scanners still the same. Replaced IPR & ICP, still no start
hot. It had a noisy clutch release bearing so we even removed
the back plate of the engine to listen for leaks in hi pres.
oil system and examine the branch tube. We could hear a leak,
it was the exhaust on the HPOP. Well we thought we may have
energized the new IPR too long and installed a new one, SHORT
retest. No leaks heard, Light at the end of the tunnel!!!
Re-assembled engine and trans, Problem still persists, no start hot. Do have code 2290 ICP too Low. We were kind of suspecting that it was
the low pressure oil system not feeding HPOP and we did get the correct fitting for our gauge to test this and during a hot crank we have 5psi and no start. Extended crank for about 20 seconds the pressure starts to climb slightly and when it hits approx. 8-9 psi it starts and goes up to 30psi at cruise it is 60psi. Took apart the front to expose the lo pressure oil pump, gears and cover damaged. It digested something. Customer states #6 injector was replaced 6 mos. ago. We understand that clips do break and come out of the injectors on these and get sucked up and chewed up. Installed new cover and gears. Still no start hot and it did not change our readings either!!! We had a different 6.0L in the shop that runs fine (just in for service) so we tested it's oil pressure hot with the crank sensor disconnected and it only has 5 psi cranking. Evidentley this is normal. Plug in the crank sensor, hits .9v and 600psi on the scanner (hi side pressure) and starts. Our problem vehicle will not get past 375psi and we are very sure our orings all good. Any help is so greatly apprieciated.

[m-chan68]

What is the model year of the vehicle? When the vehicle reaches operating temperature, remove the oil filter, press the top of the standpipe and have an assistant crank the engine over. Does oil in the housing rise rapidly? If it does, low pressure oil system is working properly. Does this vehicle have an aftermarket oil filter installed? If so, get rid of it and replace it with the proper Ford/Motorcraft FL-2016 filter. Have you replaced the high pressure pump? If there was metal debris on the IPR valve screen, the pump needs to be replaced.

[WEWILLE]

Whats the ipr% when cranking hot?

[Danodb]

Thanks for the replys the ipr % is 85%. I understand that the 6.0L have a short life with fuel injectors. Approx 100K and they cause problems. This truck is a problem child.

[WEWILLE]

That ipr and icp tells me there is still a leak, or something. You replaced the hpop icp, and ipr correct? I would remove the valve covers when its warm and not starting and watch for oil coming out the top of the injectors between the injector and the high pressure oil manifold.

[WEWILLE]

What year is it?

[m-chan68]

Did you check the dummy rail plugs? This would be the plugs on the high pressure oil rails, opposite to where the standpipes are located, but require the same tool to remove (either 1/2" square drive, or 10mm allen head depending on whether it is an early or late-build '05 model year). Remove the plugs and pay particular attention to the lower o-rings.

[sixliterleader]

If your sure there are no leaks and it sounds like you are its recommended to replace the engine oil cooler, believe it or not it can do this same thing. One wouldn't think it could be temp related but it sure can be, the cooler likely has metal/debris from the oil pump problem (unless it was replaced and you forgot to mention it) The base oil flow test is good but can fool you sometimes. Good luck with this.

[stang8989]

Did you ever find a fix for this truck??? I have one with the exace same symptom and I can't find a leak in mine. I have replaced the High Pressure Oil Pump, IPR, ICP, Stand Pipes. Thanks

[Danodb]

Originally Posted by stang8989

Did you ever find a fix for this truck??? I have one with the exace same symptom and I can't find a leak in mine. I have replaced the High Pressure Oil Pump, IPR, ICP, Stand Pipes. Thanks

We did finally get this truck back many months later and it was running very poorly. We did a compression test and found 2 cylinders with only 100psi compression. This engine was horribley abused and was dying and that was the source of all of our grief.