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    6.0 Late 2004 Hardstart - Nostart - Diagnostics

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    vixentd
    This document provides diagnostic steps for troubleshooting a hard start or no start condition on a 2004-late build Ford 6.0L Power Stroke diesel engine. The steps include performing a visual inspection, checking for trouble codes, testing glow plug operation, fuel pressure, injector operation, and monitoring key engine parameters during cranking using a scan tool. It outlines specifications for each test and states that if the concern is resolved by a test, further testing is not required.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    6.0 Late 2004 Hardstart - Nostart - Diagnostics

    Uploaded by

    vixentd
    289 views1 page
    This document provides diagnostic steps for troubleshooting a hard start or no start condition on a 2004-late build Ford 6.0L Power Stroke diesel engine. The steps include performing a visual inspection, checking for trouble codes, testing glow plug operation, fuel pressure, injector operation, and monitoring key engine parameters during cranking using a scan tool. It outlines specifications for each test and states that if the concern is resolved by a test, further testing is not required.

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    Ford

    Original Title

    6.0 Late 2004 Hardstart_Nostart_Diagnostics

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    This document provides diagnostic steps for troubleshooting a hard start or no start condition on a 2004-late build Ford 6.0L Power Stroke diesel engine. The steps include performing a visual inspection, checking for trouble codes, testing glow plug operation, fuel pressure, injector operation, and monitoring key engine parameters during cranking using a scan tool. It outlines specifications for each test and states that if the concern is resolved by a test, further testing is not required.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    289 views1 page

    6.0 Late 2004 Hardstart - Nostart - Diagnostics

    Uploaded by

    vixentd
    This document provides diagnostic steps for troubleshooting a hard start or no start condition on a 2004-late build Ford 6.0L Power Stroke diesel engine. The steps include performing a visual inspection, checking for trouble codes, testing glow plug operation, fuel pressure, injector operation, and monitoring key engine parameters during cranking using a scan tool. It outlines specifications for each test and states that if the concern is resolved by a test, further testing is not required.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 1

    -NOTEIF CONCERN IS FOUND, SERVICE AS

    REQUIRED. IF THIS CORRECTS THE


    CONDITION, IT IS NOT NECESSARY TO
    COMPLETE THE REMAINDER OF THE
    DIAGNOSTIC PROCEDURE.

    F-Super Duty/Excursion/Econline 2004 - Late Build


    6.0L Power Stroke Diesel Engine
    Hard Start/No Start Diagnostic Guide
    DEALER NAME

    CUSTOMER NAME

    MODEL YEAR

    P&A
    CODE

    VEHICLE SERIAL N0.(VIN)

    CHASSIS STYLE

    VEHICLE GVW

    ODOMETER

    ENGINE SERIAL NUMBER

    TRANSMISSION

    1863 CLAIM NUMBER

    AMBIENT TEMP.

    DATE

    CUSTOMER CONCERNS (Please list in this box)


    TYPE OF SERVICE

    6005E

    6005E

    FICMLPWR
    FICMVPWR
    RPM

    Check if the WATER IN FUEL lamp has been

    seconds
    Wait to Start Lamp "on" time is independent from g/p "on" time

    Glow Plug Resistance


    Disconnect the 4-pin connector at front of valve cover
    Measure each Glow Plug resistance to Bat. ground.
    Measure engine harness resistance to GPCM

    8 volt min.

    100 RPM
    minimum
    ICP
    3.5 mPa min.
    (500 PSI)
    ICP volts
    .80 V min.
    FUEL PW
    500 S - 2 mS
    FICMSYNC
    Yes/No
    A - B+ - If low voltage condition is present, check battery,

    sample from fuel control module.


    Cetane rating between 40-50 is recommended for

    Check

    6005E7

    Verify that the fuel pump has voltage and gnd. At key on.
    Measure fuel pressure at engine fuel filter housing test

    port with a (0-160 PSI) gauge at key on.


    Fuel pump runs for 20 sec. at key on and pressure
    falls after key off.
    Instrument
    Spec.
    Measurement
    0-160 PSI
    45 PSI min.
    Gauge

    charging system, or power/gnd circuits to the PCM.


    B - FICMLPWR - No/low voltage indicated could be caused
    by 12-way connector issue or logic power fuse.
    Refer to Pinpoint S for detailed 12-way conn. diagnostics

    C - FICMVPWR - No or low voltage indicated could be caused


    by 12-way connector issues.
    D - RPM - Low RPM can be caused by starting/charging
    system issues. No RPM indicated while cranking could be
    CMP or CKP faults.
    E - ICP - A minimum of 500 PSI (3.5 mPa) is required for

    If pressure fails low go to next step to verify no restriction


    6005E8

    the injectors to be enabled. No or low oil in the system,


    system leakage, injector O-Rings, faulty IPR, or high
    pressure pump could cause low pressure.

    Measure restriction at fuel pump inlet.

    Measurement

    IPR duty cycle defaults to 14 % (300 PSI) w/o CKP signal.

    If > 6" Hg restriction, check lines between pump and fuel tank.
    If < 6" Hg, inspect both fuel filters. If filters are OK, check fuel
    regulator. If regulator and filters are OK, replace fuel pump.

    Glow

    Glow Plug

    Harness to

    Plug
    Number
    #1
    #3
    #5
    #7
    #2
    #4
    #6
    #8

    to Ground
    .1 to 2 ohms

    GPCM connector
    0 to 1 ohms

    140
    120
    Time (seconds)

    illuminated.
    After verifying that there is fuel in the tank, drain a

    6005E4

    parameter list and monitor while cranking engine.


    Parameter
    Spec.
    Measurement
    B+
    6005E6

    Spec.
    6" Hg MAX

    (Dependent on oil temperature and altitude)


    Relay on time
    Spec.
    Measurement
    1 to 120
    B+

    Scan tool may reset below 9.5 volts.


    Select the parameters indicated from the scan tool

    4. Sufficient Clean Fuel

    6. Electric Fuel Pump Inlet Restriction

    glow plug "on" time .


    Turn key to run position, measure voltage ("on"time)

    If self test codes are retrieved, go to appropriate PPT test.

    10. Scan Tool - Data List Monitoring

    Check

    5. Electric Fuel Pump Pressure

    Using the scan tool GPCTM and EOT pids, verify

    click in sequence 1-8. Sequence repeats three times.


    Injector
    Trouble Codes

    Inspect air filter and inlet ducts.


    Inspect exhaust system.
    Check if air filter minder indicator has been illuminated

    Instrument
    0-30 " Hg
    vacuum

    6005E3

    Use scan tool. Injector DTC's will be displayed at test end.


    All injectors will momentarily click, then each injector will

    3. Intake/Exhaust Restriction

    optimum start.
    Method
    Visual

    comes on between 1 and 120 sec., and does not come


    on at all if oil temp is above 131F.
    Using a scan tool , check Continuous and KOEO DTC's.
    If codes are present go to Pinpoint Test AF.
    Verify B+ voltage is being supplied to GPCM.

    Trouble Codes

    9. KOEO Injector Self Test (Click Test)

    Check

    Method
    Visual

    6005E3

    Use the scan tool.


    DTC's retrieved during this test are historical faults.
    Diagnostic

    Check for contaminants (fuel, coolant).


    Correct Grade/Viscosity.
    Miles/Hours on oil ,correct level.

    Method
    Visual

    and altitude. The Glow Plug Control Module (GPCM)

    Trouble Codes

    8. Retrieve Continuous Trouble Codes

    2. Check Engine Oil Level

    6005E5

    GPCM Operation
    Glow Plug ON time is dependent on oil temperature

    Diagnostic

    Fuel Oil Coolant Electrical Hoses Leaks


    Method
    Check
    Visual

    COMMERCIAL

    11. Glow Plug System Operation

    Use scan tool. DTC's set during this test are current faults
    6005E

    1. Visual Engine/Chassis Inspection

    6005E2

    7. Perform KOEO On-Demand Self Test

    NOTE: A hard start/no start concern with EOT


    Temp. below 60F perform step 11 first.

    PERSONAL

    100
    80
    60
    40
    20
    0
    0

    20

    40

    60

    80

    100

    120

    140

    EOT (F)

    Add 5 seconds to glow plug on time when above

    7000 feet in altitude, but not to exceed 120 seconds.

    F - ICP V - Voltage reading below spec indicates low ICP


    during crank.
    G - FUEL PW - Pulse width defaults to 0 w/o CKP signal
    H - FICMSYNC- No sync could be caused CMP or CKP faults.

    Refer to PC/ED section 4 for detailed test procedures.

    See PC/ED manual, Section 4 for more detail on all of the above test steps.
    When troubleshooting a Hard Start / No Start or Performance concern, this form must be filled out to the point of repair and returned, to receive warranty credit for diagnostic time
    for the parts listed below.
    Fuel Injectors (9E527), regulator-injection control pressure (9C968), pump assembly-high pressure oil (9A543), turbo charger assembly (6K682), fuel control module (9G282), FICM (12B599), PCM (12A650), EGR valve (9P452),
    CKP sensor (6C315), CMP sensor (12K073), GPCM (12B533), and Glow Plugs (12A342).
    Some labor operations are listed in more than one test step. Those operations include time for all occurrences and can be claimed only once.
    What problems were found and what repairs were performed?

    List Part Name, Number and Serial Number of parts replaced.

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