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Very green newbie here, Throw to into the fire right after passing my last Diesel class. I have a 04 F-250 6.0 with 99,971 miles for a crank no-start. Followed all pc/ed hard/no-start sheet checks all pass until #9 koeo injector self-test passed but I noticed only 1 faint click during the test ? Ficm L and V pwr and sync are good. Was confused in which direction to go from here as no specific pin-point test seemed to be lised or my brain was over loaded and I just didnt follow the chart right ? I took a good injector and plugged it into each plug on the injector harness and got a loud click on each one when power was applied ? What may I be over looking ? I tried to keep things simple and followed the diag sheets closely before asking for help. Any opnions or help would be greatly appreciated..

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Well, did you monitor ICP pressure while cranking? Is ICP volts 0.2 at KOEO? Does ICP volt climb to 0.8 volts/500 psi while cranking? How are the rest of the PIDs? What were the DTCs retrieved? Have there been any recent past repairs showing up in OASIS? Did you verify good fuel pressure/quality?

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Well, did you monitor ICP pressure while cranking? Is ICP volts 0.2 at KOEO? Does ICP volt climb to 0.8 volts/500 psi while cranking? How are the rest of the PIDs? What were the DTCs retrieved? Have there been any recent past repairs showing up in OASIS? Did you verify good fuel pressure/quality?

Icp volts 0.3 KOEO, Approx 1.47 volts cranking . icp pressure climbed over 1000 psi cranking, vpwr over 12 volts, rpm signal was good. fuel quality is good, pressure was 50 psi koeo and 53 cranking. oil level was good, looks like oil was just changed. KOEO self test Pass ODDTC's. Had p0266 memory code, cleared and recieved p1000. Cust stated that a independent shop had looked at his truck and told him it has blown headgaskets and to take it to a Dealer. Was very evasive on providing any other info about any other repairs peformed. Last repair listed on oasis was 9-06 for an egr valve.
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Welcome to the DTS Shane!

 

Some things to chew on...

 

Is the ICP sensor on the HPOP cover or is it on the right valve cover? Is the ICP PID voltage between 0.18 and 0.24 volts (Early Build) or 0.15 and 0.35 (Late Build)? Late build has the ICP on the valve cover and your reading of 0.3V would be in spec - but if your ICP sensor is the early build then the sensor is biased. The old sensors are known to fail; come apart, leak oil and read inaccurately when this happens.

 

I find that your fuel pressure being higher when cranking is odd. I have never really checked fuel pressure while cranking but it seems odd that it would rise if the injectors are using fuel and the starter is drawing a lot of power. Add to this the P0266 injector code and you might suspect fuel aeration affecting bank 2. Just a wild theory but I have seen trucks in our shop towed in with a bad injector causing a no start.

 

Does the engine TRY to start? Any smoke? Ignition knock?

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With only one faint click, and a reported "pass" from the injector electrical self test, there is a strong possibiity that the FICM has taken a dump on itself.

 

If so, here is an instance where experience and observation help out. Machines talk to us in many ways, not just check engine lights and DTC's. Listening to the sounds an engine makes can be just as valuable as the code you retrieve.

 

We've performed injector electrical tests so many times, the sound is burned into our cerebrums. When one doesn't sound the same as we'd expect, it sticks out like a sore thumb.

 

Once we find that sore thumb, it may be time to divert from the PC/ED. The test reports passed, right? The PC/ED then tells us to go to the next step. But no clicky, no starty. It's time to figure out why the injectors didn't click, but the FICM has no problems to report.

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I took a good injector and plugged it into each plug on the injector harness and got a loud click on each one when power was applied ?

Yeah good point Greg, was it ONE click, or a short BUZZING?

 

To further help you with this see TSB 04-18-6 and see THIS POST for the 6.0L noid light tool and injector circuit tester which helps with this.

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There is also the possibility that the injectors are sludged up and will not move. Try a known good ficm and see if that changes it. But if you hung a known good injector on every cylinder and it clicked while the old injector did not I would suspect sludged injectors.

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Did just that today, Took a known good ficm, Re-programmed it to the truck and still only one click and still no start it seems like it wants to. No smoke , No knock. Used the good injector and plugged it into each plug on the injector harness and had power(click and buzz )to each one again, I suspect a lack of maintenance so I am now waiting for maintenance records of some sort. as for Mr. Browning's question , it is a late build as the icp sensor is on the valve cover, finally got some help from another Diesel tech and he said same thing, Either FICM or bad injectors most likely from sludge. I was thinking since I have power to all plugs on the injector harness with either FICM that I can lean towards an injector concern and wait for the cust to supply maint records.

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