First, I know that there are a myriad of threads on here that discuss crank, no start issues, but like most people, maybe I'll determine in this process one of the 1 in a million issues that no one has had and we'll learn together; so here goes.
My truck description: 2003 F250, 6.0L, build date of February 2003, 141,000 miles on the engine. EGR
cooler and oil cooler replaced around 85,000. Blue Spring mod, and FICM
with Atlas 40 tune from Ed at FICMrepair.com. I also run a MBRP Installer Series 5inch turbo back straight exhaust, and a Banks Six-Gun with the Banks IQ and now a ScangaugeII.
In September of 2018 I started having issues with the truck not starting when above normal operating temperature. It would start cold ok (little longer than normal crank time), but if I got to operating temperature and shut off the engine, I would have to wait until the engine oil temp was under 115*F to restart. Sometimes this would take several hours, just depending on the time of day and ambient temp outside. My Banks IQ was reading codes P2290, P2291, P2623. I was on my way to a fire call in the truck and I lost all power. I couldn't get above 50mph regardless of how high my RPMs went. Once I got to the scene the truck died and wouldn't re-start. Had to have it towed home. 2 days went by and I got it to start so I could turn it around in the driveway. After watching every video that DieselTech Ron had to offer, I determined, it to be the HPOP
. based off of the reading from the "Fuel Pressure" gauge on the Banks IQ. This reading was 100psi. Now I know that that is an inaccurate label of the gauge as there is no means to read fuel pressure without installing a gauge on the fuel filter bowl, but that reading should be coming from the IPR
. I changed the IPR
, and HPOP
Last weekend I finally got all the parts in, installed and the truck back together. In the process, I had to replace the wire harness ends for the VGT solenoid, IPR
sensors. I also tore apart the turbo and cleaned and anti-siezed all parts. I replaced the turbo mount bolts and drain tube with parts from Bulletproof diesel. Also replaced all the o rings and gaskets for the turbo. New engine oil and filter (15w-40 Shell Rotella T4 and motorcraft filter) and new fuel filters. Got it all together and it fired up fine. Had a small exhaust leak but other than that it was doing good. I drove it with no issues other than extremely low boost(maxed out at 5-9psi), I believe due to the exhaust leak around the up and down pipe on the turbo, for 3 days. On Saturday I retightend all the clamps and it seemed like the leak was gone. I took it out for a test drive and when getting in the throttle pretty heavy, it would generate up to 20lb of boost. On the way back into the neighborhood the truck shut off like I turned the key off. I coasted into the neighborhood, tried to restart it, but no luck. I opened the hood and smoke was coming from under the turbo, in the area of the HPOP
cover / turbo drain tube. Also had a burning oil smell.
Just got my scangauge II in the mail yesterday and got it setup with all the Xgauge parameters. So here are my numbers. Also changed the batteries today. Had them on a charger all night and still only mustered up 11.2 volts.
Key on Engine Off
SYC: 0 FCM: 48.0 IPR
: 14.8 ICP
: 42 Volts on the battery (measured with multimeter): 12.48
Key on Engine Cranking
SYC: 1 FCM: 48.0 IPR
: 84 ICP