Injector replacement

[Stupiddawg]

Ford F-250 Super Duty Powerstroke 6.0 Turbo-Diesel

Cold Start problem with a P2285 code at 109,000 miles. Runs great when warm. Had the Turbo replaced and the IPC Sensor and pigtail replaced at 95,000 under warranty. After getting the code I called the dealer and found out I should have taken it back then and had them recalibrate. I took it back and they re-flashed the computer with all the new stuff and they still got the P2285 code. They kept the truck so as to start cold the next morning while having it on their computer - it would not start at first but they finally got it going. They told me now that I have a leaking ICP sensor and it needs to be replaced again. Injectors 4,5 and 6 need to be replaced - all for just the paltry sum of $2,800. $1,200 in just parts. I cannot afford this and the $64.00 question is. 1) Could the leak at the ICP sensor be giving false info and causing the injector readings to be false because it would have lost prime at start up? And if I have to replace 3 injectors at 109,000 miles (strange) do I have to take the Turbo off (real big question)? I live in a rural area and nobody has a manual. And any other suggestions as to possible alternative options. I'm pulling the little hair I have left out about this.

[ford_doctor]

The ICP sensor is a pattern failure on the early build 6 liter engines with the sensor mounted on the high pressure oil pump. When the sensor is leaking oil it is failing. You may experience hard starting, stalling and surging just to name a few symptoms. I would recommend replacing the sensor AND the harness connector at the ICP sensor. Do this and re-evaluate the running condition of your engine before condemning any injectors.

[GrampyJim]

I'm getting a little confused reading your post..... The ICP and pigtail were replaced recently but have failed again? Could this be a case involving service part warranty?

Things aren't adding up for my addled old brain....

[ford_doctor]

That does sound funny now that you point it out. I haven't seen any fail that quickly. On top of that the old ICP sensors can be replaced with the new style which don't come apart or leak.

[OT]

S..what yr. is your 6L? 04 ICP alot easier to replace than 03. To replace f.i. you gotta remove valve covers, so look at e. Lost our free link for svc. manual. R U planning on DIY repairs or ?.

[Stupiddawg]

Thanks guys - your good. In reply it is a 2004 with the 2003 6.0. I am going to do the work myself, at least the Sensor part. From the bottom have been able to locate the 3 wire pigtail and am pretty sure I can replace without taking the valve cover off unless I am missing something. I'm a fair backyard mechanic but have never dealt with Turbo stuff or diesel but boy am I learning. If it gets to the turbo being removed I think maybe I will have someone else do it (what do you think) but if it does not need to be removed to get to the injectors I can do it - do you know if you need to remove Turbo? Again thanks and have already referred other Diesel Heads your way.

[Stupiddawg]

I'm new here and I guess this is how I reply to your post. Ford declined any warranty. I forgot to add this part in the last reply post I did a few minutes ago. Also that dealer went out of business.

[RatherBNtheWoods]

The turbo comes off to get the right hand valve cover off, to replace injectors. Removing the turbo will not be/is not the most difficult step in r&r'ing an injector!

[Stupiddawg]

Replaced sensor and the truck has no codes and runs great. However as a note the sensor we took off was of the old type and not the new one that supposedly does not leak. If you remember Ford was to replace this sensor 10,000 miles ago (about 8 months). They say basically tough luck and does not matter which one they replaced it with but they replaced it.

Thanks for all your help - saved me $2,200.

[ford_doctor]

Originally Posted by RatherBNtheWoods

The turbo comes off to get the right hand valve cover off, to replace injectors. Removing the turbo will not be/is not the most difficult step in r&r'ing an injector!

The turbocharger does NOT need to be removed to replace fuel injectors on a 6.0L PSD.

[theclient]

Ford Doctor - Is there a way of looking at the ICP and telling the old style from the new style?

[banditboy]

Hi! not sure about code or wat is wrong with the engine, but if you decide to do repairs your self get alldata online manual its 30bucks but it is worth it. ALLDATAdiy.com :: Leading Source of Diagnostic and Repair Information check it out, it been helpfull to me with turbo removal, egr removal, its got all specs, diagrams, and everything u need to work on your truck.

[fusaichi pegasus]

Originally Posted by Stupiddawg

Replaced sensor and the truck has no codes and runs great. However as a note the sensor we took off was of the old type and not the new one that supposedly does not leak. If you remember Ford was to replace this sensor 10,000 miles ago (about 8 months). They say basically tough luck and does not matter which one they replaced it with but they replaced it.

Thanks for all your help - saved me $2,200.

The work peformed should have a warranty for 12 months or 12,000 miles reguardless of weather the original repairs were made under your base 5 year 100k warranty. I havent seen a repeat failure of and icp sensor after the updated one and pigtail were PROPERLY installed. I would almost want to lean toward a biased sensor or faulty splice of the pigtail. In a rare case you may have heat damage to the wiring if the insulation wasnt routed properly after the first repair.

[GrampyJim]

Originally Posted by ford_doctor

The turbocharger does NOT need to be removed to replace fuel injectors on a 6.0L PSD.

X two....

[ford_doctor]

Originally Posted by theclient

Ford Doctor - Is there a way of looking at the ICP and telling the old style from the new style?

The old style ICP sensors are made of brass with a black plastic top. The new style sensors are silver, made with a stamped steel body with a black plastic connector.