Hey everyone,

I've got a 2003 F350 XLT 6.0 daily driver with 6,000 miles on a full engine rebuild, 160,000 miles on the chassis, from the main bearings to a new head to about every sensor on the damn engine. ARP head studs were installed, Bulletproof EGR cooler, new Oil Cooler, FICM went to Ed @ ficmrepair.com, 4" turbo back exhaust, and a sinister coolant filter summarize the EXTENSIVE list of parts that got installed.

Now, Before the rebuild I had an undiagnosed stall after start condition. After cold soak <8 hours @ 70*F, the truck would start, and immediately stall. This would repeat several times before operating normally.

After the rebuild, the condition remained. The fuel pump then got replaced, Blue spring upgrade, 8 new injectors (these were planned anyway), IPR, and still the condition remained. Not one single code. ICP was good, but *appeared* to drop out after start on my autometer gauge. My OBDII scan tool is too slow to see if that's correct. LPOP and Oil pressure regulator replaced with rebuild. HPOP puts out 3,636 psi @ WOT according to my scan tool (remember - '03).

Last week or so, the engine started intermittently missing. While misfiring, I pulled up the computer, power balance showed #8 low. Injector disable test confirmed the injector was not functioning. I unplugged the #8 injector and tested with a brand new navistar injector, still in the bag. Nothing - the injector didn't click at all. Reconnected #8 injector. I Went through the FICM connections and found one of the connectors was loose. I Corrected and retested. Injector pre-cycle sounded like more than one hole wasn't working. I tried to start the engine, but it would not run on its own. At least three injectors were not firing. I did more fiddling with the connector. Finally got it 'clicked' in on both sides. Truck fired right up and ran great. Cleared all the codes I caused and called 'er good.

Driving home that night, I felt an intermittent miss again in the engine. When I got home I pulled up the codes and this is what I found.

P0269 - Cylinder 4 Contribution/Balance
P0282 - Cylinder 8 Injector Circuit Low/Open
P0460 - Fuel Level Sensor Circuit
P2287 - ICP Sensor Circuit Intermittent
U0105 - Lost Comm. with FICM
P2552 - Throttle/Fuel Inhibit Circuit

I zip tied the connectors on to the FICM in an angry rage but it still does it. All PCM connectors are tight and undamaged. I'm guessing a wiring harness issue, but which one? The P0460 and the P2552 have me confused! Everything is on the Injector harness except those and the U0105. And what about the stall after start?! Where do I go with that?

I'm getting really frustrated with my truck and I want to get her back on the road. I would like to have a little direction on this before I go throwing parts at it again. I appreciate any and all help!

 

Seems like it could be a ficm harness issue. Would also be nice if you could borrow a diff. ficm just to make sure there are no connection issues within the pins of the ficm itself. The injector harness that plugs into the ficm is known to cause issues, especially intermittent ones. Ive replaced several mainly on 03- early 04 trucks. The stall after start could possibly be caused by the type of oil filter you run. Also there have been some cases where the hpop oil resevior drains over night, this has been caused by a crack in the reservoir area, internal problem with the hpop (a check valve of some kind?) or when someone forgets to tighten the hpop bolts all the way down and/or the bolts loosen on their own. You can diag. this issue by doing a leak test on the high press oil sys.

 

I'm running a luberfiner filter right now, but the condition did not clear up with a ford filter.

i will look at the pins again this weekend. I might pull the harness off and ohm it out while wiggling the connectors.

 

Pins are all fine, harness ohms out fine, could not find any broken or loose connections.

 

Also, I cant do a leak test without ripping the top of the engine apart as my ICP sensor is on the HPOP cover. Is there a way around using that port?

Some new symptoms have come up as well. Rough Idle, and shift problems. It seems like the trans is hunting for the right gear. That happened once and I am unable to recreate the condition. No new codes, just the same ones as before.

Just today, it rough idled and i got a code for ICP sensor circuit intermittent and a fuel level sensor circuit. Those arent even on the same PCM harness are they?!

Im about ready to throw in the towel and let the stealership take over. Itll be fucked up when I get it back, but at least they would possibly find the issue... :/

 

You can remove a valve cover and use the small port on the rail. So the icp and fuel level codes set at same time?

 

That appears to be the case, yes. Ill pull the VC and leak test it this evening and post the results.

 

Just keeping this open, I've been too busy to dick with the VC. I will test it tomorrow evening when I get it back.

 

Pulled the passenger side valve cover and performed the leak test. Had to search like hell to find out how to close the IPR. After unplugging the FICM and PCM harnesses, I turned the key on and jumped pin 2 of the engine wiring harness to battery (-). Click! No leaks whatsoever.

I did find that the three FICM connectors were again not 'clicked' in all the way. Last time I played with it I made damn sure they 'clicked' in on both sides. Still no bent pins, I'm getting pissed at those connectors. They don't appear to be damaged, but I can't seem to keep them in place!!!

 

did you watch for leaks with a gauge? Its usually a very slow leak, wont be audible. Are the seals at your connectors causing them to not fully seat? You can try some dielectric grease on them to help them slide in easier and fully click.