2005 6.0
Just did all injectors and glow plugs.
Worked air out of high pressure oil rail with 12 0-60 wot runs as per for TSB. now, 2 weeks later it is dying intermittently and it just took 4 bouts of serious cranking to start. ( very similar to trying to start it right after injectors.)

Well now ford wants to charge me 2000 to replace the ficm( tester goo month ago) and replace te dummy plugs in the HPO rail. Well the plugs were just replaced and I just pulled ten out again and they are fine.

I also drove the truck today and it dies afte 10 minutes of driving like it does and was long crank and would restart. Drained the batts. We ended up having to pull start it and I started after the first clutch pop. It then idle without issue for the next 1.5 hrs. No issues.

My problem is I put my scanner on and the icp is within spec (high 500s psi) at idle and round .80v. And when i rev i rises accordingly. The FICM is also working as well. I don't believe it's bad but I can't figure what's goings on. We also manually tested the FICM about a month ago and it tested fine.

I did just pull that HPO rail again and retighten the injectors and they all needed tightening. Not much but they werent Torqued properly.

When pulling that Valve cover it wreaked of fuel. So much so that removing that HPO rail made my eyes burn. And te truck does seem to be running rich.

So recap:
1) ford says bad dummy plugs and bad FICM
2) we just did plugs and tested FICM
3) truck dies after warming up and is hard to restart
4) after hot truck dies it will pull start(manual trans) on the first clutch pop
5) truck will die hot but upon restart will idle forever. We idled it for multiple hours after it died hot
6) codes are all injector circuit low and something about FICM

I'm at my wits end. Please help!!

 

First things first, why were all 8 injectors replaced? Where did the new one's come from? Who did the work?

Your ICP readings, are they actual or desired? Compare both. Also give us some more readings like driving down the road or WOT blasts.

Test the FICM again, it's easy and only takes 15 minutes. The test procedure is at the top of the 6.0 page. Report back here with what you find. Also try unplugging the ICP sensor and restarting, see if that helps. It's in the passenger side valve cover.

 

When you say it's in te pass valve cover what do you mean? Specifically.
Yes, all 8 injectors were done. Myself and our other mechanic did the work. And the injectors are motorcraft new.
I have both HPO rails torn off right now so I'll have I wait to put the scanner back on.

Anything I should do or check whole the HPO rails are off?

 

I always torque injectors to about 28ft-lbs, not the 24 they call for. Also since you have the oil rails off did you put new standpipes in, they are not supposed to be reused but if they are the newer style with the teflon backer on the orings then they can be reused, without the teflon backer they are known to leak. Has the STC fitting been replaced on the High Pressure Oil pump ?? they are also known to go bad/they will go bad/ especially on the 05 trucks, it is just a matter of time.
If you smell fuel under the valve covr then the safe bet would be to pull the injectors again and inspect the orings, the only way fuel can get inthere is through the orings. With the oil rail off it will only take a couple minutes to reove the injectors.

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Oh, and on the pass side valve cover right behind the glow plug module you will see the ICP sensor, it goes in right through the face of the valve cover, just unplug the connector and see what it does.

 

How difficult would it be to replace the stc fitting on the HPOP?
Can I so it with just the valve covers off and HPO rails?
And do I need to remove the HPOP?

 

No need to remove the HPOP, turbo comes off, HPOP cover comes off, it's right there on top. The kit comes with an alignment tool to put it on right. It's cheap too, like $38 or something.