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Old 09-24-2014, 01:54 PM   #1
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TWOLOST: My own trip with the 6.0L PSD (2007)


I loaded up my daughter in our van a few weeks ago to go and visit my dad. This is something that I do almost every week. Along with visiting my dad and spending more time with my daughter... this also gives the van a good couple hour run each week. Unlike all previous trips this time we hit a showstopper. While entering an on-ramp about a mile from our house the van just died. I tried restarting it on the fly but it would not fire. Turned over strong… just no combustion. I managed to coast to the side of the on-ramp and out of the way of others with little drama. After a few attempts to start the engine and some cursory looking for obvious issues under the hood… we called for tow (which was less than two miles back to our house). I have spent the last two weeks pouring over the Internet and building some context of what the problem might be. As those of you that own a 6.0L PSD... may be familiar with you have quite a selection of ‘context’ to choose from. I think that there are more weak links on the 6.0 than a tow chain made purely of candle wax. It seems like many of the weak links can be addressed... with very deep pockets.

This had been the only time my van ever left me stranded (thankfully).


The short story is that I don’t know what is wrong, yet. Real testing begins next week when I get my fuel pressure gage.

Here are some historical facts/data (related to this specific issue or not):
  • Vehicle is a 2007 Ford E350 that Sportsmobile extensively built out to an SMB 4x4[/*:m:7wjuksrc]
  • I am the original owner[/*:m:7wjuksrc]
  • Engine is a 2007 Ford 6.0L PSD Turbo.[/*:m:7wjuksrc]
  • Vehicle currently has 52,000 miles on it[/*:m:7wjuksrc]
  • Engine has had zero modifications except for an AMSOIL remote filter system and a RAVELCO anti-theft device.[/*:m:7wjuksrc]
  • Engine oil and filters have been changed every 5,500 miles (with the exception of one oil change during an extensive Alaska trip that lasted 8,500 miles).[/*:m:7wjuksrc]
  • All oil changes utilized AMSOIL 5w-40 100% synthetic Diesel Oil[/*:m:7wjuksrc]
  • Engine coolant has been flushed and replaced a total of two times (by Ford)[/*:m:7wjuksrc]
  • Engine fuel filters have been replaced once (by Ford)[/*:m:7wjuksrc]
  • I started monitoring engine diagnostic data when the engine threw its first code. Since then, I have been using an Edge Diesel Evolution tuner for this task[/*:m:7wjuksrc]
  • This engine has always started right away and has run very smooth (for what it is) - even on the day it died[/*:m:7wjuksrc]
  • Engine had thrown the following codes over its lifetime:[/*:m:7wjuksrc]
  • The first code ever thrown was on 05/08/2012 after climbing Hardscrabble along the White Rim Trail in Utah. Each subsequent series of codes thrown on our UT trip was in extremely hot temps.[/*:m:7wjuksrc]
  • 05/08/2012: P0404; EGR valve position control or range fault[/*:m:7wjuksrc]
  • 05/08/2012: P0405; EGR sensor “A” circuit low[/*:m:7wjuksrc]
  • 05/14/2012: P0404; EGR valve position control or range fault[/*:m:7wjuksrc]
  • 05/14/2012: P0405; EGR sensor “A” circuit low[/*:m:7wjuksrc]
  • 05/22/2012: P0404; EGR valve position control or range fault[/*:m:7wjuksrc]
  • 05/22/2012: P0405; EGR sensor “A” circuit low[/*:m:7wjuksrc]
  • ----------[/*:m:7wjuksrc]
  • 11/08/2013: P0478; Exhaust pressure control valve malfunction[/*:m:7wjuksrc]
  • 03/08/2014: P0299; Turbocharger/Supercharger Underboost[/*:m:7wjuksrc]
  • 03/08/2014: P0478; Exhaust pressure control valve malfunction[/*:m:7wjuksrc]
  • 05/20/2014: P0299; Turbocharger/Supercharger Underboost[/*:m:7wjuksrc]
  • 05/20/2014: P0478; Exhaust pressure control valve malfunction[/*:m:7wjuksrc]
  • *** After engine died and I was trying to re-fire ***[/*:m:7wjuksrc]
  • 08/03/2014: P2291; ICP Too Low – Engine Cranking[/*:m:7wjuksrc]

Based on some research I was doing, I purchased ScanGage II pre-programmed for the Ford 6.0L PSD. The critical datapoints are as follows:
  • FICM Main Power: FMP = 47.5V (Key On Engine Off) (looks fine)[/*:m:7wjuksrc]
  • FICM Sync: SYC = 1 (looks fine)[/*:m:7wjuksrc]
  • IPR (KOEO) = 14.9 (looks fine)[/*:m:7wjuksrc]
  • IPR (Start) = 85% (bad)[/*:m:7wjuksrc]
  • ICP (KOEO) = 0 psi (fine)[/*:m:7wjuksrc]
  • ICP (Start) = 0 psi (may builds to 13 psi in 20 seconds)[/*:m:7wjuksrc]

Engine currently turns over strong but there is no sign of combustion. Juice from batteries are good. From the above telemetry, the IPR should not be anywhere near 85% (max open). Also, ICP needs to be 500 psi to start. Not much going to happen at 0 - 13 psi.
At this point I am working my way back toward the fuel tank (relatively inexpensive) rather than working forward toward the High Pressure Oil Pump (astronomically expensive). If it turns out to be anything anywhere near the HPOP, then I will address a number of other weak points as well (everything other than taking the heads off/apart). All work will be done by me. Another sad fact is that anytime I have let anyone else (Ford/Ravelco installer) work on this rig... I end up fixing their newly created mess anyway.

More to come...

Cheers,
TWOLOST + 1
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Old 09-24-2014, 01:59 PM   #2
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Re: TWOLOST: My own trip with the 6.0L PSD (2007)

I'd doublecheck Ravelco wiring... Could be something simple.
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Old 09-24-2014, 02:05 PM   #3
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Re: TWOLOST: My own trip with the 6.0L PSD (2007)

It can often just be a bad ICP sensor! Or a bad solenoid. Both are more common that a bad HPOP. However, and filtration issues (when was the reverse amsoil install problem?) can cause the HPOP sump screen to rupture which then can cause damage.
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Old 09-24-2014, 03:41 PM   #4
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Re: TWOLOST: My own trip with the 6.0L PSD (2007)

Sorry to hear it, TL. I've had to get a tow a few times and always used a flatbed. That tow job looks scary.
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Old 09-24-2014, 04:12 PM   #5
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Re: TWOLOST: My own trip with the 6.0L PSD (2007)

Sounds nearly identical to when I lost my HPOP in 2006 which left me stranded. Ran fine, then just died while driving. Cranked easily with no sign of life. Luckily, I was under warranty back then. I hope it is not, but that is my bet.

Good luck and keep us posted.

Phil
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Old 09-24-2014, 04:48 PM   #6
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Re: TWOLOST: My own trip with the 6.0L PSD (2007)

Same thing happened to me...faulty IPR VALVE. HPOP was fine.

FROM 2008: viewtopic.php?f=13&t=2101&p=17497#p17497

RETRIEVED CODE P2290 ICP LOW. MONITOR THE DATA LOGGER. ONLY 52 PSI. LOOK UP OASIS FOUND TSB 8-16-6. PREFORM AIR PRESSURE TEST AT THE PUMP HAS LARGE LEAK. NO CHANGE WHEN CYCLING THE IPR. REPLACED THE IPR. CLEARED CODES. RETEST PASS. ROAD TEST PASS. STEAM CLEAN.

FP NUMBER 5C3Z-9C968-CA----------------REGULAT 135300-------QTY-1
W300013-------------------------BOLT 848795-------------QTY-1
W300051-------------------------NUT-L 845202------------QTY-1
[EDIT] Ford said they did replace the ICP sensor while in there

BTW Ford charged me 100 bucks but sent me a check back for 100 dollars.
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Old 09-24-2014, 06:49 PM   #7
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Re: TWOLOST: My own trip with the 6.0L PSD (2007)

Crank motor while observing oil pressure....need 500 to pop off injectors

not 500 then unplug IPR connector, this will send into default, crank again while unplugged and check oil pressure.

Not 500 then HPOP is bad
Yes 500 the IPR is bad
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Old 09-24-2014, 07:40 PM   #8
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Re: TWOLOST: My own trip with the 6.0L PSD (2007)

Quote:
Originally Posted by hogasm
Crank motor while observing oil pressure....need 500 to pop off injectors

not 500 then unplug IPR connector, this will send into default, crank again while unplugged and check oil pressure.

Not 500 then HPOP is bad
Yes 500 the IPR is bad
Damn, that's good info to share!

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Old 09-24-2014, 09:37 PM   #9
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Re: TWOLOST: My own trip with the 6.0L PSD (2007)

Quote:
Originally Posted by hogasm
Crank motor while observing oil pressure....need 500 to pop off injectors

not 500 then unplug IPR connector, this will send into default, crank again while unplugged and check oil pressure.

Not 500 then HPOP is bad
Yes 500 the IPR is bad
That's a good test for the ICPR (regulator). It will not however rule out a faulty ICPS (sender). Unfortunately the test for that is "replace with known good unit". But still easier than pulling the HPOP.
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Old 09-25-2014, 11:03 AM   #10
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Re: TWOLOST: My own trip with the 6.0L PSD (2007)

Sounds very similar to the problems I encountered with the PCM (TSB 10-12-6) and FICM. If it is the FICM, i believe it should still be covered by the Ford warranty. Good luck.
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