you have one of two issues and both have been covered.
first is exhaust in fuel. not a hard test, takes 10 min you should really do it.
second a ficm issue, yes, yes you have 48v, so what there is more to a ficm then voltage output.

you have spent alot of time and money tring to fix this so far. Maybe a little more diag will go along way.
fyi Im leaning to exhaust gas issues, but have see same from ficm's

 

Well taken cheezit's advice I did the exhaust in fuel test well guess what there is definetly air bubbles coming up. I filled the resevoir then pulled the fuses the fuel would not stay above the stem. with not doing nothing air bubbles continued to come out of the driver side head. cranking it over and it continued to bubble up. only old injectors are 2,4,6 then all the rest are new.
I left the valve cover off and cranked the truck over and oil seems to be coming out of all three old injectors. I think the o-ring that the oil rail slides into is maybe gotten hard or just worn out. I notice these o-rings dont come in the injector oring kits.
What should I do the truck has 185,000 on it.

 

I guess many others have. I think it is usually a install problem when the rail was installed last. Maybe contact Alliant for those O-rings. I know I have seen them for sale someplace, although I dont think they are available from ford.

Try this... AP0002
http://www.endurancepower.com/v2/con...er.htm#ANCHOR8

 

Those bad oil pressure o-rings (I have never had to replace those without replacing injector first) won't cause combustion gas in the exhaust though. The pucks (the part that slides into the injector and screws into the oil rail) can leak as well. But not very likely. If you can get it started and you have excess fuel in the exhaust and white smoke, you have a fuel/injector problem, not a high pressure oil problem. Oil is supposed to drain from the injector, so leakage (drainage actually) from the injector is normal operation. Just not too much to cause a no start, hard start, or no/hard start hot.

I had one that the injector did not get tightened down from the factory enough, and the copper combustion gasket burned out and then eventually burned out the fuel o-ring on the injector causing fuel to dump into the cylinder and combustion gas to aerate the fuel and causing it to start, then die and not restart for a short time.

I would check your #8 injector installation first, then the rest of them, considering you have combustion gas leakage on the driver's side. Sometimes the copper falls off and you miss it when installing the injector. I had that happen once, but caught myself when I saw a new copper sitting around. Good thing I hadn't put it all back together yet.

 

I replaced the other three injectors today and it started up really good and it seemed to run fine. Reved it on up and it had no hesitation let off the throttle and it idled rough then eventually died like it did before. Tryed starting it back but all it done was crank over. let it set for a min and cycled te fuel pump and it started back up again.
There is still a bunch of smoke coming out of the exhaust. fills the shop up quick.
Buzz test no codes present
koeo had a ckp code so i replaced that
now the only codes im getting is a P2284,P0281,P0263
According to the scanner the P2284 is a icp circuit range/perf. does that have anything to do with the ipr valve?
ipr% running is jumpy around 28-30 but I think it went to 38% when I reved it up.
Thanks

 

the p2284 is all icp sesnsor/connector type issues. Ipr should be 22-24% once all the air is out of the system.

 

Have any ideas to what it can be now cheezit? I cant believe it runs good and revs up fine to but then just falls on its face.
would that p02284 code be the icp sensor bad? I tryed to unhook it then it just dies.

 

p2284 is basicly saying there is a difference between commanded and disired icp,
I would have to know icpv and icp# both koeo and koer to make a suggestion.

 

Im wondering if it could be the ipr bad or going bad. That and the cam sensor is the last thing I can think of that would might make it do this. Im getting rpms running so I think the cam sensor is ok (maybe).
The ficm off the wrecked truck wouldn't have to be programmed would it. It was a 04 too.
Cheezit im going to get the info you was needing tonite. I have a new ipr laying here but was wanting to find out if a bad one would make it act the way it is or not. The truck is at our other shop about 15 miles away and have no internet service there.
Also just curious shouldn't the truck still run with the icp unhooked bad or not?
Thanks for everyones help much appreciated!!!

 

Well I tested some moreand heres what I have now.
koeo: icp (v) 0.25
icp psi 0
ipr 15%

koer: icp (v) 1.54 jumps up to 2.54 seconds before it dies
icp psi: 995 psi
ipr 32%

I notice as it was cranking over and it wasn't starting the icp (v) jumped from 1.40 to 2.57
I did the fuel test again and guess what I have bubbles coming up thru the stem in the center again? I know I installed the injectors carefully and torqued to specs. why do I still have bubbles when all eight injectors are new?
The koer test showed 1,5,7 injectors contibution fault.
I did a koeo test and a buzz test before I done anything and both said no codes present?

 

Sounds like your injection pressure system is good.

I would see about those bubbles. If you unhook the two fuel lines that go to the heads at the bottom of the filter housing, one at a time, you can check to see which head is causing bubbles in the fuel system. Install a gauge with a hose on the line going to the head and crank/start (whatever it happens to be) and see if the pressure increases. If so, the head that the fuel line goes to is leaking combustion gas into the fuel system.

You lubed the o-rings with oil before installation to keep from damage during install?
All the copper gaskets are present and did not fall off? Usually a missing copper will allow the engine to run for quite a while before combustion gas burns the o-ring out, so I don't think that really is the case considering all injectors are new, which come with all new o-rings installed.

You can pull the injectors out and re-install them with reusing the o-rings when the o-rings are new, as long as you are careful. They aren't as susceptible as the old 7.3 injector o-rings that you never reuse. So if you are worried about pulling them back out to inspect, I wouldn't hesitate to reinstall the injectors with the o-rings because the engine has not run long enough or got hot enough to weaken them in any way.

Are you replacing injectors to cure this problem? Was this the main reason for replacing the injectors?

I don't know what else could cause air pressure back through the fuel system...Dead head fuel system (no return after injectors), injector cups can't leak combustion if cracked without getting fuel and/or combustion gas into the cooling system. A cracked head MAYBE, but I would think you would have cooling system problems first before this type of problem.

 

First off thanks for the reply,
I lubed all the orings before installing them. I notice also the return was bubbling all the time. Is that normal?
I installed the injectors due to 5 had a high circuit or low cirrcuit code and with 185,000 on the truck I always heard when they start to go the others are not far behind.
at least the truck when it does start it revs right right up fine not like before just to 2,000 rpms before it dies. Still smoking really bad it will run you out of the shop if you leave the doors closed.

 

So is it normal for air bubbles to be coming from the return tube constantly?
Nobody has a pic of the black stem inside the fuel filter housing I think there is something broke on this one. Dont know if that would cause bubbles or not.
Thanks