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Hi I'm a ford senior master diesel tech and I would like to help you out. Lets look at your current no start issue, The problem is that you have 0 ICP cranking. ICP is injector control pressure. basically your high pressure oil pressure. It needs to reach a minimum of 500 psi before the pcm will tell the ficm to fire the injectors. So a high pressure oil leak is your problem. First to check the low pressure system verify engine oil is full, then remove oil filter and use a screwdriver to close the drain back valve at the bottom by pushing it down and have an assistant crank the engine. If the oil filter bowl fills up with oil then the low pressure system is ok. If it does not then you have a low pressure system concern, if it is aerated with tons of tiny air bubble then you also have a low pressure system. If the low pressure system proves to be ok then your problem is most likely in the high pressure system. Since it is at 0psi cranking your stc fitting may have broken and that is a very common failure on 05-06 powerstroke diesels. The other possibility will be the IPR valve but from my 14 years of experience a bad ipr always generates at least some ICP while cranking. Fo example if the IPR failed wide open the high pressure system should display the same engine oil pressure as the pressure system while cranking, usually 20-30 psi. Since you display 0 it tells me you have a large high pressure oil leak most likely from the stc.
As far as your previous hard start cold and hot you may have another issue going on there. FICM sync displaying 1 is unclear to me. The ford scan tool I use will display Ficm Sync as YES if its good. That proves cam/crank sensors are ok. High pressure oil leaks from a leaking but not failed stc fitting will cause an extended crank/hard start when hot but typically not cold. When cold and will not start you want to check your ficm M power to the injectors, this can be viewed as a pid on the scan tool or manually checked at the injectors or by using your dvom on one of the small bolts under the ficm service plate with the key on. You want to check it as quick as possible after it is keyed on. you need 48 volts, anything less than than 45 will cause hard starts when cold. if the power starts at 48 and then continues to drop when keyed on then the ficm is weak and will need to be replaced as well.
If you have any other questions or concerns please write back. Thanks
Yes the dealership sells the upgraded stc fitting that is all one piece and will not break.
You could still crank it and check for low oil pressure when it is apart but you have to have the oil filter housing in place and unplug fuel pump if lines are disconnected to prevent shooting fuel everywhere. If you IPR valve screen is damaged a new ipr valve would be a good idea while your in there as well
ok sounds good thanks. Remember it will take excessive cranking to fill and bleed air out of the high pressure system before it fires. Don't expect it to start with a five second crank it will take alot of cranking. Thanks
No if the oil filter bowl fills up that means the low pressure system is ok and the problem is most likely high pressure.
Yes the low pressure oil system should be fine if it filled up. Did you replace the stc fitting and put the pump back in the truck? Did you crank it for 2-3 minutes to bleed air out of system and build high pressure oil. If so what was your high pressure oil reading when cranking?
If you are getting 0psi of ICP pressure when cranking, there is a problem with the high pressure oil system such as an internal leak.
You are still getting no ICP pressure, when you unplug the ICP sensor, the PCM sees that the signal is gone and automatically defaults to a preset reading, that is what you are seeing on the scan tool, it is not an actual reading, only what is preprogrammed into the PCM. when you replaced the IPR screen was the old one damaged or pushed in?
Okay, then you most likely have and internal leak, there at special tools that block off the oil rails to test the high pressure pump, if you could borrow them or know a mechanic with them, that would be your next step, then an air test to see if you can pinpoint the leak with the sound of air escaping. Being a 2006 model, it most likely is a leaking dummy plug in the oil rails.
I will get you the tool number and supplier, it will take me a few minutes.
Yes that is where the iCP sensor is going to read the pressure from the pump to the rails, this eliminates the injectors. I looked on advance and they don't list it, but I found this site.
If there are no leaks and you have tried a new IPR and still no ICP pressure, then the high pressure pump must be defective.
I would pull the valve covers and check the oil rail dummy plugs before going after the high pressure pump, if they have not been changed for the updated part, it would be wise to do so anyway.
Yes that is correct, you will be able to tell if it is the dummy plug or possibly one of the injector orings.
Yes that is the dummy plug, it is a common failure for the orings to blow out the new part has updated and tougher orings.