I have a 04 6.0 with a no start. Truck is stock, I have owned this truck for 10 years and have done all the work on it since I owned it and it has 390,000 miles on it. Had issues with intermittent starting or dying during driving. I use AE to pull codes and monitor. When I would get it home before now and check, truck would start and no issues. This last time when I got it home, checked and had low ICP pressure, about 300 to 450 psi. Stayed right under the 500 psi to start. FICM voltage good at 47 to 46 VDC while cranking. FICM sync at 1 while cranking. IPR goes to 85 percent and stays there. So I pulled the IPR, no visible issues on the IPR, but the wires for the connector was chaffed. Replaced with new connector pigtail. No change, still had same issue. So I ordered the IPR adapter to do a pressure test for leaks. While waiting for the adapter to come in, I used the old IPR connector to apply 12 Volts to the IPR and check pressure. When I did this is slowly picked up the 600 to 700 psi then shot up to 1800 psi, so stopped cranking and disconnected the connector from the IPR, not wanting to damage it. So I used some shrink tube to cover the bare wires when I made up the wires to apply 12VDC to the IPR. So I switched out the new connector with the old one and plugged in the IPR. Before I plugged the FICM back in, used AE to monitor pressure while cranking. ICP climbed slowly but got to 1200 psi, I assume the air in the system caused the slow climb to pressure. IPR was at 85 until pressure reached above 500 psi, then went down to about 40 percent. Plugged in the FICM and tried to start. I monitored the IPR, ICP pressure, ICP voltage, FICM main power and FICM Sync. same issue as before, pressure would never get above 500 psi and IPR at 85 percent, ICP voltage climbed to 1.4VDC, before cranking was about .6VDC. IPR adapter came in and stripped everything back off and checked for leaks. No leaking can be heard, also had a gauge to check leak off, as I wasn't for sure that it was a small leak and could not hear it. Does anyone know how to check if the FICM is the issue or is it leaking injectors.

 

If your getting good readings from the FICM typically it means its good. But what do I know as I had a no start issue the other day on my truck and replaced my FICM relay and truck seems to be okay right now. Your FICM can show it reading good voltage but still be the culprit at least that's the consensus around here so I wouldn't rely on the voltage.

 

Your first issue to resolve is the ICP pressure that won't reliably get above 500 psig.

Don't jump to leaking injectors just yet. It sounds more like a weak HPOP to me. I would do the air test before spending money on a FICM. Since a FICM can go bad on the power or the logic side, it can be hard to troubleshoot. IMO (most of the time anyway), if you have good MPower, good logic power, FICM sync, and you pass the injector buzz test, then you need to be looking at things other than the FICM. That said, the only way to actually verify a FICM is working is to send it to a company like FICMrepair.com, Swapping it out w/ a known good one is a good troubleshooting technique .... if you have access to a known good one.

Is your HPOP original?

Is your 04 an early or a late 04 (ie where is your ICP sensor)? If it is a late 04, do you know if the dummy plugs and standpipes have ever been updated?

In doing the air test, listen for leaks at the oil filter (remove cap and filter) and at the oil fill nozzle and the ccv take off (drivers manifold).

 

^^^^ Mark is spot on in regards to your issue with the low ICP and its followed by high % values in the IPR as well. You likely have either a leak or like Bismic said a bad HPO pump. This is where you need to focus your time on first.

Answer his questions and he will work through the issues. He is one of the forum Gods, lol thats fact btw.

Good Luck with it

 

did the leak test heard nothing at any of these points, as stated I had a pressure gauge on it, closed in the valve and waited for 20 minutes without drop off.

without the ficm, I am getting 1200 psi and with 12VDC applied to the IPR without the ficm installed I got 1800 psi. so I don't believe I have a leak.
I did check the ficm relay, swapped out with the other relay, no change????

 

 

You mentioned not hearing leaks and that the pressure did not fall off. However, I can't tell from your post what pressure you got it up to when you did the "leak off" test. I also can't tell if you were pressuring it up with air (or a gas), or just from cranking w/ the IPR commanded shut w/ 12v applied to generate all the pressure.

Can you clarify that?

I am also unclear on why you think air in the system would make it climb slowly. I didn't see where you opened up the HPO system, except maybe to put the gauge on (which I assume was at the ICP sensor location? I can swap ICP sensors and my engine starts normally and builds pressure normally.

I agree w/ mhatlen's post, I can't see the FICM making any difference in the cranking ICP pressure at this point.

I assume that when you had 12v applied to do the pressure test that you had the FICM relay out or the FICM unplugged? That is the way I read it anyway.

After all that, you said it stayed under 500 psig. It won't start w/ it that low and I don;t believe it is the FICM as originally posted.

An air test is better for leak detection

 

Since you really do think it is your FICM, I would suggest you contact Ed at FICMrepair.com and run your issues by him. Better to call (IMO) so you can explain the details.

BTW - the ICP voltage at 1.4 volts corresponds to about 1000 psi, even though you said it never got above 500 psi. If it wasn't reading 1000 psi at 1.4 volts, then you have a sensor or wiring issue. KOEO, and before cranking, the ICP volts should be around 0.2 or 0.3, not 0.6. 0.6v is around 350 psig.

 

Air test was done with an IPR adapter and the gauge was inline with a valve in place before the air line quick connect so I could isolate inlet air once the pressure reached 125 psi, my air compressor is set at 125 psi. I removed the oil fill cap, remove the cap on the oil filter bowl and removed the oil filter. The driver side cover was opened already when I removed the plenum for the turbo. I had the gauge on since I didn't remove the HPOP cover, I monitored leak off to let me know there is a leak I could not see or hear.
I could not see where having the FICM installed should make a difference either that why I was stumped. But the only part with the FICM installed is it controls the injectors so wasn't for sure if something could happen with the injectors that could affect the pressure.
I have learned everything about the 6.0 on this site and Diesel Tech Ron, that is why i have gotten this much done so far. I always found my solutions on this site when I could figure it out myself. But I searched for several hours before I posted about it. Your help is much appreciated.
I assumed a good ICP, since it was showing pressure with and without the IPR with 12VDC applied. I even actuated the IPR to about 40 percent while trying to crank, with the FICM installed. As I said with the FICM not installed the IPR would appear to actuate by itself. But even when I actuated the IPR, the pressure never went above 500 psi.
After cranking should the pressure bleed slowly or drop off. Mine drops off to about 30 psi then drop slowly or I should say the ICP shows the pressure drop off then at about 30 psi it drops slowly.

 

The Ficm is like trickery to HPOP numbers

It sees the pressure and tries to turn on but its so short lived the oil pressure falls flat cause inject turn on lets out oil and in turn pressure Falls and it shuts off or stops its FPW Attempt again maybe

you would have to see FPW and it might be fast Blip across the system

another note when air test a HPOP swash plate Design the Position of the HPOP at the time of test Plays and can mess with your test results unless its total catastropic failure on the HPOP

 

Im not saying to do it but this truck would probably pop off with a shot of either and run like crap

 

There seems to be something wrong in the correlation between your voltage and the ICP pressure reading. I would sure check the ICP accuracy again!
Ford Values
Voltage...PSI
0.2............0
0.4.........200
0.73.......400
0.9.........660
01.2.......800
1.4........1000
1.6........1200
1.9........1400
2.1........1600
2.3........1800
2.6.........2000
2.8.........2200
3............2400
3.3.........2600
3.5.........2800
3.8.........3000
5............4045

The affect you are observing of the FICM sure seems odd to me.

Benny - From what I read, the FICM ISN'T seeing the required pressure. He is only getting that when the FICM is NOT installed.

Edit - I guess you are saying it happens so fast (getting over 500 psig pressure) that he doesn't see the ICP get to 500, AND the engine doesn't fire because of no fuel? So are you thinking that his FICM is the cause?

 

with the ficm out of play (no spool valve action) the system is basically deadheaded so that explains him being able to attain Higher ICP in this senereo

the only difference being the FICM unplug vs plugged

The ficm is responsible for the ICP pressure difference when these two senereo are compared

I believe he is seeing the effects of a weak HPOP intensified by putting ficm in play
He cranks it ICP slowly build the PCM tries to fire injector spools for split second but ICP pressures fall at that moment due to low volume/low ICP from HPOP so PCM stops its attempt to fire the spools and it a vicious cycle repeated many times Holding ICP in this 500 range

 

its a trick LOL

you can uplug ICP to fool pcm but the inject intensifier piston still needs that 500 psi at steady rate to even push out the fuel in inject

I think he proved the FICM IS indeed good working order by difference in HPO numbers

 

Needs a HPOP