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04 6.0 runs with ICP unplugged/dies instantly when plugged in

18K views 4 replies 3 participants last post by  bucky beavever  
#1 ·
just replaced the HPOP and put it together to this.
dies instantly when ICP is plugged in and crackles like it wants to start monetarily then just cranks. basically a no start if i plug it in with the engine off.
when running with ICP unplugged, it fires up fairly smooth then quickly gets rough. sluggish on gaining RPM's. should have all the air out by now.
seemed to run just a little smoother when at operating temp but not much. does start easier warm.
my biggest issue is this is a ranch truck way up in the sierra's on a cattle permit. i dont have anyway to check parameters, it cant be towed out from where it is. i had to build some fittings to diagnosis the HPOP with gauges.
IPR screen is updated and in good condition.
fuel pressure pegs a 60 psi gauge. (60 psi is all i had avail.)
4 pin FICM and voltage tests 47.7 - 48.3 vdc.
double checked the injector harness connections.
plugged the injector harness into the FICM on the tailgate, they both snapped in nicely and the main harness snapped nicely in also.
fresh oil and filter.
new coolant.
did all the HPO updates last year along with surfaced the heads and studs, Bullet Proof EGR cooler, remote mounted air cooled oil cooler and filter.

dumping a ton of money in this truck and it seems like it always broken, this time in a very bad place. been using a quad to get to it til it can be driven out.

they only thing sketchy is the MAP rubber hose end is looking like it may be cracked, i will replace it next trip up there.

all advice is welcome
the forest service really wants me to get this truck off their road and have been very patient.
 
#2 ·
Most of the time that problem is a bad ICP sensor itself. The reason your truck starts with it unplugged is that the pcm defaults to a pre-determined pressure to fire the rig up when it doesn;t sense the ICP. When you plug it in the pcm is calling for the 550 and up psi to fire it off but the ICP sensor won't allow it.
Could either be wiring right at the sensor or the sensor itself. The fact that it builds pressure with it unplugged is a good sign that the IPR and pump are in good order. Focus on the ICP and the wiring to it.
 
#3 ·
thank you Thuglike
i was guessing between the ICP and IPR. in my head, the IPR is working because i can throttle it. low power but gains RPM's.
i had 1 extra of each that may or may not have been bad but my buddy put them all in the same box and mixed them up when we were cleaning up. i used on of each to build test ports to isolate the pump and may have mixed them up. basically i may have made a tool from the good one, lol.