Names Jon, I am a mechanic but the current situation I find myself in, well, I wish I had a degree as an attorney.

I am from PA and had a shop times got bad had to get a job. Know I am working in CA for a few months and my warranty is up. Love the truck hate the rep. Took the truck to a local place that works mostly on the power strokes. Had them install head studs and put the First Coast Diesel delete kit on and installed the 155 injectors. They said "Your trucks ready do you want us to put the rest of these parts on?" I said I can handle it. So I go to pick up the truck and The owner says to me "The trucks not running right and we don't know what it is."

Truck starts acts like it is running on 6 cylinders, warms up and runs almost right. hesitates bad lag, wants to stall. No soot but the exhaust is rather loud under the hood. I got the anti freeze and oil temp difference code. Tore into the motor and found that the factory y pipe was not cracked but the flange on the new replacement pipe was bent out of sorts. Explains the loudness and the turbo lag. Next came the intake... HAHAHA

So I must say Adam at First Coast Deisel carefully packs these things using tape over all those holes... You would think that it would be easy to remove it all. The inlet between to the intake for the coolant passage had 4 mil tape on it and had completely sealed the inlet and not ruptured at all. Explains the temp code. Now I have not gotten the truck together yet but I am worried the new head gaskets or the new heads might have cracked. Any ideas as to the why the truck runs and hiccups every where. I have a new IPR and ICP will be checking the hpop and the orings for leaks.

Thanks for any ideas...

 

I'm confused...

Is this YOUR truck, or this is a customer of your's truck? So he brought it to you, and you brought it to LCD? Is that right?

Sounds like LCD messed something up, why isn't it being brought back there?

Or did they do the work, the customer doesn't want to deal with them, and he brought it to you?

The more details you can give about why it went in, what it got done and what it's doing now, the better...

So how does the truck run now that you've figured out the exhaust leak and coolant blockage. I still don't follow where exactly the coolant flow was blocked, forgive me.

Is it still sounding like it's running on 6 cylinders? What tuning is being used to control the new sticks? Who's injectors are they? Heard similar horror stories with some no-name injectors.

 

First thanks for getting back to me. It is my truck, I took it to one of the local shops here in CA. I wont drop there name unless they don't take care of things as far as my time etc. They are my old injectors redone to 155's stock nozzle. Warren diesel did these. I am not running a tuner yet only because I haunt decided which to get. Leaning towards the Sct. As to why I wont let them pick it up to attempt to fix it? They had tried and given up. Asked me to let them know what's wrong with it. They also new I was a tech and that I had more parts and custom work to do my truck. When I get all the work done I will run it on the ids and if there is still an issue they will be picking up the truck. I have no faith in them to properly diagnose the problems after what I was told and what I already found.

 

Man it's tough to say.

Can you elaborate more on the 4 mil tape stuck on a coolant passage, I'm not quite following what happened there.

It sounds like the truck has never run correctly since the injectors were put in right? It's possible they weren't tightened down all the way. I would start with making sure all of the clips on the harness going to the injectors are fully seated, I've seen this a few times.

If you have IDS, this might be real easy to find... I would definitely try and figure this issue out BEFORE going further with other mods, you're just going to compound issues here I think. Let's get this resolved, then go on with other mods. Especially if this other shop is going to be at fault, once you do MORE work to it they're more than likely just going to pass the buck and say "look at all this other stuff you did, you probably messed it up"

Can you monitor ICP actual against ICP desired, and IPR % duty for us?

I doubt you blew gaskets or cracked a head in that tiny amount of time. Most drag guys hard fill their blocks and don't even use coolant in some cases so...


SCT for sure, nothing else is going to allow you to use those injectors properly and keep the trans alive while doing it. Custom tunes should come from Innovative Diesel, Gearhead, GoGo, Mike@KEM or someone like that. Name brand only here...

 

Here are the pics. Thanks for the tip on the injectors. I will check that when I am checking all the hpop orings. We used my injectors for the build and they worked well before warren got them. The ficm was sent back to swamps and they checked it and put a microprocessor in it to eliminate the ficm code due to the higher voltage. Also put the 40 hp tune in it. I replaced the fan clutch and waterpump. Fan clutch was trashed and water pump impeller was about a 1/4" chewed up evenly on the face of it. The oil cooler is in good shape but I am replacing it while I have it torn down. Let me know if those pics don't work.

 

Pics work... how the fugg do you forget to remove the tape from that and install it, man would I be pissed. I would 100% without a doubt figure this out ASAP, and don't do any more "mods" to it until you do, because if something is fugged up, I'd be on the phone with that shop ASAP.

Ok, reading more, I'm comforted slightly more knowing you're using good people on this, ie Warren and Swamps. I didn't even know Swamps had something to eliminate the FICM code... interesting. Just so you know (you probably already do) it doesn't actually toss a check engine light, just a soft code if you pull it up on the scanner. Did you go with the 58V I'm assuming?

Sometimes those injector o-rings can be a pain to trace down, sometimes you'll see they're blatantly torn.

Being an 05, do you know if the STC fitting was done? What about the stand pipes and dummy plugs? If you have to dig into it again it might be a good idea to just replace this stuff, it's known failure points, Ford has upgraded all of them, and they're not expensive (relatively). STC fitting is like $50 or less, and the dummyplug/standpipe kit is like $120ish.

 

Nice quad by the way, have a c'dale quad all gncc ready. I will put some pics up tomorrow after I take some.

Most of the updates have been done but not by me. I tore into it a year or so ago after I had it to the dealer for a new turbo and an oil cooler. There was a bill with some other parts charges there that they said where needed for the warranty so I did not question them to hard. The hpop was done so really didn't look much farther though I bought a new kit and plan on installing it myself just to be certain I have the dummy plugs and the new stands and will check them out and replace them as well as the blue fuel spring.
I learned a long time ago that if you try to skimp on the quality of parts that is the same quality the job will turn out to be. That being said throwing money against a wall doesn't amount to much either. I believe the micro processor and the flash from swamps are relatively new. It is a 58v unit, will let you now how they work when I get them on.
I was actually amused, at first. They said "There was a lot of tape sorry I must have missed it." Then I was angry. Really???
I wonder what would have happened to me if my boss said Jon why is that 8,000.00$ compressor burnt up that you just installed and I said oh sorry I forgot to take the tape off the back of the oil pump.
As far as the mods I am done for now. I wanted to get everything finished at the heart of this motor before I put her back together. Turbo and tuner are the only thing on my agenda and that won't be until it runs right. Though I still have to polish and port match the inside of the headers. Oh forgot to mention I had the heads sent out and decked as week as checked for cracks and valve seals put in. They said everything looked good.
I have a hard time believing that not having a tuner on would make it run like that. Thats what they where thinking at the shop, guy says put in a new ficm, I have em on the shelf, and get a tuner thats sitting next to it and all your troubles will go away. I didn't say much... I just my butt off.

 

the good news is that there should be no damage done by that tape, yeah your oil got a little hotter than the coolant but it is the same as a clogged up oil cooler and there are people that have probably run for years with them like that, me included. I know of at least one shop that offers the intake with the water pasages sealed up, heads should be fine. how long has the truck run? you need to put a good 40 miles on it to get all the air out of the high pres. oil lines. Hopefully they went with stock Ford head gaskets, the black ox head gaskets are too thin and wll fail in short time, FYI, the stock head gaskets come with new standpipes, that is why I brought that up. Right now I'm leaning towards a injector problem, these injectors are alot harder to make right compared to other ones. If you find a loose injector pull it and replace the orings, there like $5 a set for each injector, that will definately cause problems and is hard to determine which injector it is because the combustion presure enters the fuel rail and can effect any injector on that side of the motor.

 

The truck was run for 60 miles by me. They ran it for about the same I was told. They also said that it already had upgraded dummy plugs and stands so they did not install new ones. I have to believe it is going to be orings or a loose injector because the truck ran great when it was dropped off. Got 16 miles to the gallon. Factory headgaskets where used. They told me the truck ran good when it was first started then slowly started to have a problem. It progressively ran worse for me when I picked up and brought it home. Ran it to work for 2 days to se if it would straighten up and the second day it would barely start. I live about five minutes from work and it was so hot when I parked it that it took about 5 hours to cool down enough to tear it apart when I got home the 2 day. They said they had gotten an injector code for 2 and 6 but when it first started they cleared the codes and they did not come back. There where no codes except fir the ficm code, due to the 58 volts, and a code for the Egr, due to the fact that there isn't an egr. One for the oil temp being different from the coolant.

 

Now we're getting somewhere. At least 2 and 6 are on the same bank. I think I'd be pulling that valve cover myself...