Sorry for the unclear defintion! What I wanted to express was the possibility, that the engine oil could be not the one which Ford claims to use with the powerstroke engines. I read that a wrong oil-type can lead to foaming in the high pressure system, which would explain to me the low oil pressure (ICP), but I do not think that the foaming condition will be present while cranking.
We are now trying to get the correct/higher cranking rpms and then read the ICP values. We can also change the ICP sensor + connector as suggested, but as far as I understand the system, this cannot be the cause for the not starting condition, right?
thanks again!
Eugen
As I indicated in my previous post, on a 6.0L that starts normally, if you watch ICP psi and IPR duty cycle, within less than 5 seconds ICP pressure will usually rise to about 1,200 or so psi (when only 500 is required to start), and IPR duty cycle will barely even touch 45 to 50% before the engine fires up. Again, that's on a 6.0L engine that has no issues.
On the vehicle in question, you indicated that ICP will only build to 368 psi (0.57 volts), and IPR duty cycle will reach the maximum 84.77% duty cycle (which is the highest that IPR will reach while cranking the engine). How many seconds of engine cranking does it take for these values to be achieved? What is the ambient temperature where you are located?
Again, the reason for suggesting replacement of the ICP sensor and connector are for TWO reasons. Number one, you indicated a key-on/engine-off voltage reading of 0.16 volts which is on the very low side (the range is 0.18 to 0.24 volts). This alone, tells me the PCM is not receiving accurate ICP input from this sensor. Replacing these two parts may or may not resolve your no-start issue. But, due to the high failure rate of this sensor on 2003 model years, it is highly suggested to address this NOW, so that you won't need to, in the future.
Lastly, do you have any information that you can obtain, regarding the cetane rating of the fuel in your geographic location. These engines require low to mid 40s cetane ratings to run at their optimum, which is why I ALWAYS strongly advocate use of Ford's cetane booster and anti-gel additives.