04 f350 no start after egr cooler replacement

[gengor]

Hey guys,

I have a 2004 f350, replaced the egr cooler for a leak.. After replacement and following 30km r-test it started misfiring and would not start. dtc p0603. I had the batteries disconected, tried to reprogram pcm with snap on programmer as per ssm 17571, unable to do so. Icp 1100 psi, ipr 31%, ficm sync yes, ficm pwr all good, swaped with a known good ficm, replaced injector harness, new oil, seems to have good vref, (i unplugged each vref sensor one at a time to eliminate vref concern.) I have good grounds and powers at pcm. im running out of ideas:(

[Gofaster23]

Well you've got good ICP, no signs of a leak according to the PIDS you listed. Check FICM_MPWR and make sure it's 48 volts. Check fuel pressure. Since you had the secondary fuel filter housing off for repairs you might have a substantial amount of air in the fuel system. Your symptoms leading up to the no start are identical to excessive air in the fuel system. Remove the secondary fuel filter housing, have someone cycle the key a few times until fuel spills out from the housing, tighten the cap, and crank away.

[Keith Browning]

You mean remove the secondary filter cap, right? I have had systems bind with air quite a few times and as stated, removing the cap and purging the system corrects it.

[Mbl35]

Just curiouse, were there any cylinder contribution codes when it first came in for the concern? I had one a while back just like this. It came in blowing white smoke all over and had a cyl 1 contribution code. After the egr cooler was replaced it would not fire up. First hotline had me replace batteries and the starter-no good, swap known good ficm-no good. Another call to the hotline with all voltages and icp specs good, the hotline had me change all the injectors and after some cranking it fired rite up and good. Hotline says that the coolant getting in the cylinders from a blown egr cooler forms a sludge on the injectors over time causing them to stick and fail.

[gengor]

I have good fuel pressure, i did take the secondary fuel filter cap off and blead the system... also had the fuel lines off at the housing as well..

I am now thinking that this truck needs injectors, i had 3 contribution codes before I ripped the egr cooler off. Earlier today I unplugged a couple of injectors and plugged in two older cores that I had lying around.. they buzzed with the key on b4 startup... kind of had a feeling something was wrong when i only heard #7 injector buzz at koeo, too bad i didnt persue this further a day ago:( running injector self test I didnt have any codes or indication that they were failing...

thanks for your input guys!!

[gengor]

Injectors fixed this concerns, thanks for your input!!

[mchan68]

I've had MANY trucks now, that have passed the injector buzz test, but no audible response from a few injectors during the test.

[Mbl35]

Also I remember mine was'nt precycling koeo-at least the way it should, you would hear a little fart instead of the usual harmonious rattle of the injectors. When I rnr all inj. It had that nice and healthy sound.