Compression Ignition Addict
Join Date: Aug 2008
Location: Charleston, SC
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No Start when hot
Ive been chasing a no start when hot for longer than id like to admit. I dont know the full history of the truck (late 2004 190K miles) as a buddy just bought it from an auction. He brought it to me with #5 and #8 needing injectors. I changed those out along with an oil cooler and a few other maintenance items. Oil cooler screen was the dirtiest ive ever seen but it wasn't broken as most are. I also pulled the IPR and the screen looked good.
I get the truck back together, cranks up sounds good...runs good...out for a test drive. Get back to the house turn the truck off and immediately try to crank it back up but it doesn't start. Gauge on the dash is moving so i know the LPO is good. AE shows 300psi ICP 85% IPR-i dont recall the voltages right now.
Now im thinking HPO leak even though new standpipes and dummy plugs were installed when i did the injectors. I proceed to do an air test using the ICP port and shortly after hear a air leak on the passenger side. Super, i know where its at quick fix....orrrr not. Pulled the valve cover off applied air, sounds like its coming from the #5 injector area. Pulled off the oil rail replaced the ball cup orings, reinstall put everything back together drive it come home turn off...wont crank again..air test again. Leak still coming from the same area pull the rail back off remove the ball cup i find a hair line crack in the ball cup area.
Ordered a reman oil rail as a new one from ford is 600ish. Reman oil rail has new orings and bostech ball cups. Installed the new rail put it all back together go test drive, come home turn it off try to crank it back up....Nope...icp 300ish IPR 85.
Air test again #5 area sealed but now i see oil coming from the injector oil exhaust ports on cyl 1,3,7. What the heck is this, i havnt seen this before and have a pretty decent number of 6.0s under my belt. I pulled the oil rail and use a rubber tip air blower into the injector and sure enough 1,3,7 air is coming out of the inj exhaust ports. #5 new injector no leak.
Did some reading, could be spool valves, FICM, injector harness. I Ohm out the injector harness all the pins on each plug read the same so i feel the harness is OK.FICM is a solid 48V. That leaves the injector spool valves. I ohm out each injector and they all check out comparing the results to a new ford injector. I took the spool valve assembly apart per youtube video and cleaned it with the suggested 600grit sand paper. Before i assembled the injector i installed the spool valve, applied air to the oil inlet and manually cycled the spool valve using my fingers it seems to work as it should. Coils installed and injectors installed back in the truck.
Truck again cranks up as it should runs great on the test drive no miss or hickup....back home turn it off and try to start back up....uh uh not gonna happen. Grrrr what the heck? I havnt done an air test after the test drive as i needed to step away but im still seeing 300ish psi and 85% ipr.
In any of the cases if i let the truck sit for 30 minutes it will crank back up but still not as it should. Each test drive was 15-20 miles so i know most of the air was bled out of the system.
What to do next?? I have a spare IPR im going to try even though the current one checks out ok. Maybe i just need to replace all of the injectors?
Ive read that the FICM should keep the spool valve closed when the truck isnt running. This doesnt seem to be the case but only on these 3 injectors. Heck the other side may be the same way.
If you made it this far thanks for reading! Ideas or experiences welcomed! Thanks!