Hoping someone can help she'd some light on problems with a friends truck I'm working on. He has had the truck for 1.5yrs and it has about 138,000 on it. I'd like to trust the previous owner that said all recalls have been fixed but we don't know. I've only worked on this for the past week off and on but he told me the FICM was replaced about 6months ago and the truck ran fine for a month. After a month, cold start / no start started. After trying for 1-2 hours, the truck would sometimes start or not at all. The last time it ran ok, a shop advised him #5 and #8 injectors needed replaced which I did a week ago. Truck ran fine after the long process of getting it started then started fine a few times, thought we were good. He drove it the next day about 10 miles and would not restart.

To this day, we still get the same codes (sorry I don't have the numbers in front of me)...
MAF sensor / BARO
Fuel Injector Control Module Performanc​​​​​​e
​​​​​​OBD system readiness test not complete
Camshaft position signal output circuit / open
Crankshaft position signal output circuit/ open
Initialization failed to complete
#1 Glow plug failure
#8 Glow plug failure
FICM voltage low
FICM voltage high
Loss of comm to FICM
Software Incompatibility with FICM

When the truck decides to start, it starts fine (quick) and runs great for about 1 hr. Then will not start for a day or 2 with all of the same codes returning. I have pulled the wire harness to the FICM and check all wires with no issues. Replaced relay with HD relay. When the truck runs, the relay is too hit to touch, even when cranking it is very warm, even the cover for the relays is discolored and has a spot that is starting to melt where the top of the HD relay now almost touches the cover. We have replaced all of the fuses regarding fuel, FICM. I have read through MANY posts on here chasing these gremlins with no luck. I am at a complete loss here. I also noticed while looking at the PCM pins, the small connector (being on my left side) the fourth pin from the left, top row is starting to "melt" the plastic around the base slightly. Sorry for the book, just trying to show some of the effort. PLEASE HELP!

 

Bump.

I would start by replacing those relays or fuses that are got and discolored. I vaguely recall the FICM must be programmed (not you the specific truck) Maybe the programming is screwed.

You really need some method to monitor the live voltages to your FICM. $25 will get your a decent OBDII bluetooth and the torque pro app for Android to read those voltages.

I know it's been almost 3 weeks since the post. Plz reply if you're still around.