Under Valve Cover Harness/Injector Misfire - Diesel Forum

MotionMan · 02-04-2010, 08:47 PM

My truck just died on me, I had it towed to a mechanic who said the left bank was dead, it had to be the harness. He pulled the cover and said the plug had come unplugged, it did not drop but just unplugged, he also said a code for #1 injector misfire will not go away. The truck does start now but runs horribly, very rough, no power. I am ready to take it to the dealer now, I am 1500 miles from home and don't trust these guys. I read about an IDM but with the dcode I wonder if it is just a bad injector. The truck has gone 217,000 and has never been on the chain...or the dealer....or a mechanic. The problem is it is cold, snowing, and I have no garage here.

**woodnthings8** · 02-04-2010, 10:26 PM

It could be a bad injector, or the harness could be damaged from coming unplugged. If you pay to have the #1 injector done by someone else, you will spend about half of a whole new set you can install yourself. Being 1500 miles away kind of forces the decision though. Injectors are not that hard to change on your own if you have a place where you can do it for the day.

MotionMan · 02-04-2010, 10:59 PM

Would you trust the dealer to find the problem with a scan? The mechanic said misfire #1 injector, I am not sure what he used to read this but I think it was Snap On. I would hope the dealer would have all the tools.

MotionMan · 02-04-2010, 11:06 PM

Another possible sympton is the truck would have no power at atrt up in the cold, I would have to drive it to get it to open up, I could floor it with nothing. Once I had to shut it off and restart it to clean it up. It just started to do this. I have no way to plug in and it has been cold but it never did this before.

**woodnthings8** · 02-04-2010, 11:23 PM

Quote:

Originally Posted by MotionMan

Another possible sympton is the truck would have no power at atrt up in the cold, I would have to drive it to get it to open up, I could floor it with nothing. Once I had to shut it off and restart it to clean it up. It just started to do this. I have no way to plug in and it has been cold but it never did this before.

that sounds like the EBPV working normal. It will restrict the exhaust to warm the truck up quicker.

Too me a dealer is a safer bet than just a random shop. It will cost more but with a dealer you have a better chance of getting it done right the first time. The other choice is look for a diesel performance shop, usually they know the trucks better than the dealer.

MotionMan · 02-05-2010, 08:24 AM

Thanks. thats the next step.....

**NorCalDiesel** · 02-05-2010, 10:03 AM

Keep us posted, please. I have the same Ex, except it is Toreador Red, and it is developing a similar problem. Never been towed or to the dealer. I hope your experience is good.

MotionMan · 02-05-2010, 10:46 PM

It goes in Moday for the CPS and a free scan....I replaced it at 100k and kept a spare International one in the truck, I replaced that first but it did not help. now the dealer can do it....with a free scan as part of the deal. I will let you know, thanks for all your help.

equipmentguy · 02-05-2010, 11:04 PM

Quote:

Originally Posted by MotionMan

It goes in Moday for the CPS and a free scan....I replaced it at 100k and kept a spare International one in the truck, I replaced that first but it did not help. now the dealer can do it....with a free scan as part of the deal. I will let you know, thanks for all your help.

That year has the split shot injectors in it. They are known for having that problem. You can use a ohm meter to check the UVC harness. Have they tried running the competency test just as soon as the oil get warm enough for the scanner to allow it? Most times when they first go bad they will check good hot and bad at first warm up factory injectors of that year are known for that.

One last thing to try is to unplug the IPR sensor. It can sometimes cause a rough idle. I doubt that is it from what you describe but it is an easy thing to check.

MotionMan · 02-06-2010, 12:42 AM

The dealer spoke of a comp test, I don't know what or where the IPR sensor is but if you can tell me I will try. I will be driving it there Mon morning so it will be warm. all I want is my truck to run, it has never failed me so this is like your kid breaking an arm.....

equipmentguy · 02-06-2010, 01:21 AM

Quote:

Originally Posted by MotionMan

The dealer spoke of a comp test, I don't know what or where the IPR sensor is but if you can tell me I will try. I will be driving it there Mon morning so it will be warm. all I want is my truck to run, it has never failed me so this is like your kid breaking an arm.....

The IPR sensor is on the valley side of the head behind the A/C comp. (you may have to remove the plastic cover over the HPOP to get to it. Unplugging it causes the PCM to go into a default mode it it smooths out the idle then the sensor is bad. Also it will set a code (CEL on).

You may have one or more injectors bad. When we check them here and they come in hot I leave them at the shop overnight and check first thing in AM and usually find more bad. It is bad to have to have that done on the road because like you said you can get a full set of aftermarket injectors for what Ford will charge to install one. Also the aftermarket injectors last a lot longer than the Ford injectors. Wait let me put my disclaimer in on the injectors (in my experience they last longer) otherwise someone will start in on how that is not correct. I have only limited experience with them I have owned them since the they came out and the company I am equipment manager for only has about 100 of them.

**woodnthings8** · 02-06-2010, 01:20 PM

It is not the IPR you unplug, it is the ICP sensor. When unplugged the PCM defaults to a 500 psi setting. This will allow the truck to idle if you have a bad ICP. The IPR is the injection pressure regulator if you unplug it the PCM will not be able to control the pressure. The ICP is injection control pressure sensor. This sends the actual pressure in the drivers side head to the PCM to determine how the IPR regulates the oil pressure from the HPOP.

The test you are talking about is the CCT (cylinder contribution test). Be leary if they tell you that # 8 needs replaced when you run this test. The new CPS tends to make # 8 fail this test by a small amount. #8 is a long lead injector, it fires right after #6 in the firing order, since they are in the same head they share the same oil. They allow #8 to spray a little more fuel to compensate for the decreased oil pressure. If they say it fails have them check the PERDELS on all the cylinders. They should be less than 4-5% to pass. #8 will usually run about 6-8% with the new CPS and under 5% with the original black CPS.

equipmentguy · 02-06-2010, 02:05 PM

Quote:

Originally Posted by woodnthings8

It is not the IPR you unplug, it is the ICP sensor. When unplugged the PCM defaults to a 500 psi setting. This will allow the truck to idle if you have a bad ICP. The IPR is the injection pressure regulator if you unplug it the PCM will not be able to control the pressure. The ICP is injection control pressure sensor. This sends the actual pressure in the drivers side head to the PCM to determine how the IPR regulates the oil pressure from the HPOP.

The test you are talking about is the CCT (cylinder contribution test). Be leary if they tell you that # 8 needs replaced when you run this test. The new CPS tends to make # 8 fail this test by a small amount. #8 is a long lead injector, it fires right after #6 in the firing order, since they are in the same head they share the same oil. They allow #8 to spray a little more fuel to compensate for the decreased oil pressure. If they say it fails have them check the PERDELS on all the cylinders. They should be less than 4-5% to pass. #8 will usually run about 6-8% with the new CPS and under 5% with the original black CPS.

Yes that is just what I call it a lot. Most people know what it is and it doesn't default a 500psi setting it causes the PCM to use a predetermined duty cycle map for the IPR instead of using the actual pressure for feedback. Hence if the sensor is bad it will smooth out the idle. It's probably not the problem anyway just a small chance and something to check.

The injectors can be real hard to diagnose on those models. The 100% fool proof way is to pull them and do a bench check, But at that point you may as well replace them because there out. I tell the guys in the shop if they find three or more bad replace the set. Even if it is from a HPOP failure and they just find trash in a couple I have them use a whole set because the others have trash in them also and usually go bad very quickly. We have around 100 company trucks all of them are Ford about 50 are 7.3s the others are 6.0s and 6.4s. We also have better luck out of Alliant injectors instead of stock Fords especially on split shots.

MotionMan · 02-07-2010, 11:36 AM

Thanks for the great tips, when I start rattling this stuff off they will be amazed

I was going to bring it in warm, now I will bring it in tonight and leave it so its stone cold. Thanks for the help, I sure hope its not too bad.....I am way way away from home and I am at their mercy, if it wern't for you guys I would be like a deer in the headlights....I would say chick but I bet there are some here who know more than me....not sure how but you never know....and I would like to meet her, its a good challenge

MotionMan · 02-08-2010, 06:17 PM

Well, it turns out the harness was bad and when the other dinks were in there they left the #1 injector unplugged. The local Ford Dealer was very good and had it done in 5 hours, the other guys took 3 days. This whole thing was a mess, I am going to go after the first guy for 1/2 of what I paid him....he screwed up in a bunch of places and he needs to own up to this.