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6.0L Power Stroke Diesel 2003 - 2007 F250, F350 pickup and F350+ Cab Chassis, 2003 - 2005 Excursion and 2003 - 2009 van

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Old Sep 12, 2012 | 09:47 PM
  #1  
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Confused?

I'm trying to diagnose my 03 F250 6.0 for no start condition.
Truck died when driving back home 50 feet away from my driveway and won't start anymore. Currently waiting for SGII to have a whole picture, but meanwhile I tested FICM module and looks OK 48.4V KOEO and when cranking, fuel pump is working OK to. One thing is not clear to me when testing ICP sensor using DVM. Several posts states that voltage should be .25V with key ON and min. 0.8V when cranking. My readings are 1.32V with key ON and aprox 7.6V when cranking?????
Any explanation for that, what I'm doing wrong
Thanks in advance,
Darek
 
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Old Sep 12, 2012 | 10:35 PM
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Assuming your hooking the DVM up to the ICP sensor RIGHT and DVM dialed into the Correct setting Your ICP sensor Is BAD
 
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Old Sep 12, 2012 | 10:36 PM
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Unplug the ICP sensor and Try to Start it
 
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Old Sep 13, 2012 | 11:33 AM
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Thanks for replays.
Think I'm doing this right. I stripped insulation from two wires going to the sensor and tapped my DVM right there. My Fluke DVM is st to DC Volts, range 1-30V.
What is not clear to me if sensor is bad higher voltage readings should make FICM "happier" thinking that oil pressure is high, unless is looking for specific range
 
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Old Sep 13, 2012 | 11:35 AM
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Try what Benny suggests ^
 
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Old Sep 13, 2012 | 11:39 AM
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I did try to start with sensor unpluged. No difference
 
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Old Sep 13, 2012 | 11:42 AM
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Did you read for codes?
 
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Old Sep 13, 2012 | 11:44 AM
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Originally Posted by dasio
What is not clear to me if sensor is bad higher voltage readings should make FICM "happier" thinking that oil pressure is high, unless is looking for specific range
The PCM uses Actual ICP to control the IPR valve in a closed loop, so a voltage reading of 5V or higher probably confuses the PCM into opening the IPR valve as far as it can to reduce the pressure lower than the ~4000psi the computer thinks is happening. When you unplugged the ICP sensor that forced the PCM to use desired ICP to control the IPR, but since it didn't start the sensor is either OK or not bad enough to cause this on it's own.

But if it died while driving, it's probably worse than just a sensor. Pull the IPR valve and see if it's filter screen is cracked, if it's stuck in an open position then the truck won't build enough HPO pressure to start.
 
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Old Sep 24, 2012 | 12:52 PM
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Oops! my mistake.
I was testing IPR thinking is a IPC. This truck is new to me and I'm not very familiar with. I used to turn wrenches for living but on foreign cars and I'm retired now.
Any way, I've spent few evenings lurking around this great forum educating myself about "6.0 No start Problems" and here it's what I've determined so far.
After finding ICP (behind IPR) and disconnecting it truck started, but run rough and felt like some cylinders are missing. After engine got warm, won't start anymore.
Replaced ICP.
Truck starts now. But same thing, only when cold and starts missing after idling for 10-15 seconds.
SG2 reports 800-1000 PSI when engine is cold but after gets warm and no start condition pressure is only 200-300 PSI when cranking.
Looks like I have HOP leak problem?
Did a air leak test from ICP port and I have lots of air coming from both valve covers, much less when IPR momentarily energized 12V.
Any suggestions where I should be looking next?
 
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Old Sep 24, 2012 | 01:08 PM
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Follow the hissing noises. There shouldn't be any with IPR energized. Dont keep IPR powered up more than a min or two at a time. It's a small consolation on your early engine there's no STC fitting on the high pressure oil pump to worry about, but the early pumps have a check ball in the HPOP housing that they will spit out sometimes.
 
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Old Sep 25, 2012 | 03:47 PM
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Sounds like air is coming out from under both valve covers in equal amounts, so my guess is that's coming from a crank case.
This morning I removed IPR valve, cleaned and put new seals on. After that engine started, and as usual after 15-20 seconds started running rough and missing. Five minutes later no more start.
Any other test I should do before pulling turbo out?????
 
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Old Sep 25, 2012 | 07:28 PM
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Ya post
ICP
ICPV
IPR%

we really need IPR% to

But sounds like your on the right path
 
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Old Sep 25, 2012 | 07:49 PM
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Question :
Why not bad O-rings on the stand pipe or dummy plugs
If it is running till warm? Or the top of the injectors O-rings.

Sean
 
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Old Sep 25, 2012 | 09:26 PM
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Thanks for for your help guys.
Here are some PID's I've measured now. Engine is slightly warm right now and would not start. Today was about 82*F in my neighborhood and I've run engine this morning.

KOEO:
IPC 21 PSI
IPR 14.4 %
FMP 48.5V

Crank:
IPC 200-450 PSI
IPR 77%
FMP 48.0V

I'll post idle values tomorrow morning when engine starts
 
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