Exactly one week after getting my '05 back from it's first no start issue, the truck won't start again. The first time was a low pressure oil issue caused by a WIX filter and cap. A NAPA filter and cap was installed and it has been running OK since.

Yesterday, I noticed the truck started to lope at idle. It wasn't bad, but definitely noticed it since it didn't do it before. I had filled up the day before at the same station I have used since I got the truck back. I did, however, put too much dieselcleen in on accident, upwards of 12oz. I thought maybe that was causing it so I filled up again yesterday hoping for maybe there was too much DC in the fuel system. Still loping this morning, so I read on FTE that maybe here was water in the system, so I got under there to do it. I couldn't get the plug out, so I loosened the 4 screws on the manifold and let the fuel drip out. I filled up a coffee can with fuel and decided that was enough.

I also read on FTE where someone had alleviated a stumble issue in OD with the unplugging of the EGR. So, I unplugged mine and took her for a drive. I drive about 5 miles and pulled over. Truck was still stumbling in OD and I considered plugging the EGR back in, but didn't. I turned the truck off and plugged my SCT in to check for codes and there weren't any. I started it back up and returned home. I parked the truck and still had a few minutes before I had to get dinner started, so I decided to do my high idle mod with my upfitter switch #4. I found the correct wires and had it connected in 10 minutes. I turned the key and no start. I plugged in the EGR and no start. I unhooked the high idle upfitter wiring and no start. Plugged in the SCT, no codes. I pulled the oil filter and verified oil coming into the bowl with the spring pushed down. I cranked for 30 seconds to see the oil pressure gauge on the dash jump to the middle. I have LOP, so it's not the same issue as before. What did I do?

I went in to eat, put my daughter to bed, and ran out of light. I'll get out there tomorrow to figure this out. I have the tech folder section for the no start opened on the laptop and will be on the front seat.

Frustrated and going to bed. I am at my cabin with somewhat limited tools and not much knowledge about diesel as this is my first one....moving quickly to being my last.

 

Sorry to hear about your problems. I suspect a bad EGR valve but there are many things that can cause a no start condition. You did not indicate what was looked at the first time it was repaired. It may be time to get it to a knowledgeable Ford diesel mechanic. Mike

 

The first time is didn't start, it was at the dealer and $600 later, I asked if they could change the WIX filter to an OEM filter and cap after reading on here about the issues that WIX filters can cause.

This time, I have oil pressure.

 

I can't help but think it's fuel related....I drained the water separator for the first time yesterday. I have not changed the fuel filters since I bought it a month ago. Should I do anything before I pony up and get new fuel filters?

 

Unplug the ICP and see if it will start

 

Is the ICP on the right valve cover or under the turbo?

 

Can you check FICM voltage? If you have low pressure pump, what about high pressure, can you hear injectors cycling when you turn off the engine? It may well just be coincidence that it failed again. Make sure you leave the batteries on a charger overnight between tries to start as low batts will do damage to injectOrs. Even a trickle charger overnight would help.

 

The injectors are cycling, I can check FICM voltage, but it was just resoldered about 2 weeks ago. The trickle charger was on all night.

 

That's good. Best to prevent low voltage and have to resolved again. I would get the fuel filters and make sure you get the updated drain part for the primary file bowl. Part number is 6E72-9C082-A. This is the updated part. When you change them, be sure to do lower first, drain then pull filter, then upper, the cycle key several times to ensure pressuring up. You might want to be sure fuel is coming into second bowl before filter is closed. Have someone cycle key, short bursts it comes fast. This will confirm primary fuel pump as well.

 

on a 05 it is on the passenger valve cover.

 

I thought that was it, I've gotten a few votes for both locations. I pulled the plug and still no start.

 

If you want to try something, before filters, take out upper filter and have someone cycle key to see if the fuel bowl is filling. You may need a turkey Bastet to remove excess fuel to get filter back down but it's worth a try. Does the exhaust smell like diesel from all the cranking?

 

I haven't cranked it much today, just once for 15 seconds to see the oil pressure register on the dash. I smelled the exhaust anyway and didn't notice a strong smell of diesel. A local backyard mechanic suggested ether to see if it pops.

How fast should the fuel be coming in the bowl? The truck probably needs filters, there's a date on the upper filter, 4-10...I'm guessing that Apr of 2010.

 

What are the two sensors under the turbo? One has 2 wires and one has one wire.

 

There is only one sensor under the turbo on an 05--the IPR and it's a 2 wire sensor. There is a ground wire from the FICM harness that's supposed to go to one of the intake manifold studs for grounding that will cause issues if it's not connected.

Fuel should fill the secondary fuel filter VERY fast--one or two seconds at most.