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I'm wondering if you have a HPOP issue or sensor problem. The engine needs 400psi (correct?) on the HPOP rail for the engine to start triggering the injectors to fire.
Also, I've seen people mention issues with the glowplug controller having problems, wire chaffing or connector failures causing not all of the glow plugs to heat.
I'm sure someone can chime in on what is the best way to troubleshoot this problem but I would think the HPOP and glow plug potential problems would need to be ruled out first.
I had no problem starting my '05 6.0L in Dillon, CO when it was -10deg outside, I turned the ignition on, waited for the glow plug light to go out and then waited an additional 30 seconds so they could get good and hot before I cranked and it fired on my first try. I will say it was not a happy engine, it took a good minute for it to reach normal idling speed, I did not try to move the truck until the engine had warmed up on it's own and it had ramped the RPM up to about 1200.
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2005 F-250 6.0L PSD Crew Cab 4x4
JVC XM & HD, JBL Speakers, SAS Bazookas
Added Upfitter SW's, Brake Module, BriteBox FLC,
Block Heater Harness, Leer Shell, Whelen Strobes
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