I have a 2005 Ford Excursion with a 6.0 diesel. I was driving it and had pulled into my destination and realized that it had massive oil leak and assumed that I had a “high pressure oil leak “somewhere. With a little research I started with one of the most basic things and replaced the ICP which was purchased from Riffraff Diesel (part number: 4C3Z9F838B), change the oil and tried to start it.It would not fire. I then took it to a local mechanic, and we started with a Motorcraft Fuel Injection Pressure Regulator(IPR) Part number: CM5126. This did not solve the issue. Next he replaced the HPOP this was purchased from CNC fabrication (SKU 424019). After installing the HPOP it would start but it was idling very rough, and he believed that it may have a couple of bad injectors. Next we ordered a set of remanufactured injectors from injectors direct. After installing them he couldn’t get it to fire. He plugged a computer into it and said that he verified that it was currently putting out adequate oil pressure. Checked all fuses and wiring harnesses and can’t seem to find anything that stands out. At a loss of where to go next. I did notice when looking back it did have the 03-04 HPOP and I had installed the IPR(Part number CM5126) which says it is for a 2005. Part number CM5054 says its for a 2003-2004. Could it be an issue with the wrong IPR?Any suggestions what to potentially try next?

 

Excursions had clean-up duty - they got the excess 2004 engines unfortunately.

Since you have the round aluminum '04 HPOP, you did get the wrong IPR, but I do not think that that would cause a no start.

We need cranking data to make an assessment:

• Cam/Crank Sync (also called SYNC)
• FICM SYNC
• Cranking rpm
• ICP sensor pressure, psi
• ICP sensor volts
• IPR % Duty Cycle
• FICM MPower
• FICM LPower
• FICM VPower
• Fuel (injector) Pulse Width
• V-reference voltage

https://www.ford-trucks.com/forums/8...condition.html

Scanning for codes with a good scan tool like FORScan is also imperative.

 

Where was the oil leak coming from?

 

It felt impossible to tell where the leak was coming from. Was a significant oil in multiple places!

 

Common oil leak points:
Turbo oil supply connection
Turbo oil drain connection
Oil Temperature Sensor
Oil Pressure Switch

Bottom line - if you can't find the source of a significant oil leak (or SEVERAL leaks), then how can we do that for you over the computer?
Clean the engine as best you can and have someone crank while you look for the leak(s). Ultimately, you can put DYE in the oil and get UV glasses, but a major leak should be identifiable.

With a late '04 engine (I assume your ICP sensor is on the passenger valve cover), the ICP connector/sensor is not that bad of a failure item (not like on the '03 engines anyway).

There are other areas that could leak, but aren't particularly easy fixes.

I assume that sufficient cranking was done to purge the air out of the high pressure oil system
Have you verified fuel flow (without any air in the fuel)?

 

Holy snowball effect!

Have your mechanic check the things @bismic noted:

• Cam/Crank Sync (also called SYNC)
• FICM SYNC
• Cranking rpm
• ICP sensor pressure, psi
• ICP sensor volts
• IPR % Duty Cycle
• FICM MPower
• FICM LPower
• FICM VPower
• Fuel (injector) Pulse Width
• V-reference voltage

And fuel pressure. Something on that list will point to whats going on.

It takes alot of cranking to purge the air after injectors are replaced.Even then it still needs to be driven to fully purge the injectors.

 

I think this is a little over the mechanic's head; he's working the parts cannon.

 

I was going to say the same thing. Your mechanic isn't diagnosing, he's spending $1000's of your dollars on hunches. You don't fix 6.0's on hunches.

I would find a better mechanic or guide him based on what we're telling you here. Or even better get your hands dirty and fix it yourself. These trucks really aren't that hard to work on. I can do most things in my garage on a weekend (headgaskets NOT obviously).