So In case some of ya don't know Im a mechanic, not so much a woodworker, but I don't let anybody fix anything for me, I do all my own stuff and learn as I go, whether its electrical, wood, ... (read more)landscape, whatever... now I've been a mechanic 18 years now and I apprenticed on diesels, heavy equipment, Caterpillar, Case, Cummins, etc. I know my way around an oil burner.
Recently my neighbor, who has an 05 ford F-250 Super Duty came to me and said his truck was having trouble starting, white stacking on start up and when it started it ran rough, but caught on and started running great, first thing I thought, fuel filter, air filter, he cleaned the air filer, problem didn't go away, in fact after a week the truck quit starting.
Now here's the problem, most the places I ever worked for sent Fords into the shop, we didn't touch em ourselves, most people are scared of Fords, the 6.0's are a little finnicky. I knew this was gonna be an adventure, but I was eager to learn something new.
So my neighbor called around and bugged me and we started by cleaning his EGR valve at the recommendation of a shop, I knew better, I knew it was a fuel issue, just not what. The EGR valve didn't fix the problem.
I tried a little ether,(its OK i know what Im doin, I don't recommend you ether a motor though) the truck started and ran great, like raped ape! Now I knew for sure it was a fuel problem, just where to start....
After a few calls and some internet research I was pointed in the right direction, all of the symptoms actually point directly to the FICM, or Fuel Injection Control Module, here we go.. The FICM steps up the 12 volts to 48 to operate the injectors so check the dumb stuff first, battery charge, terminal condition etc, then, you'll need to test the FICM itself.
Checking the FICM is a cake walk. Youll need a few hand tools, a DVOM, and an assistant, if the motor wont run you'll need ether (starting fluid) remove the coolant reservoir, there are 2, 8MM bolts holding it on, slide it forward, remove the right side hose and plug it so it wont leak. the FICM is on the valve cover. use a t-20 bit to remove the 2 torx bolts from the inpection cover on the FICM, pop the cover off carefully. Under the cover you'll see either 4 or 7 bolt heads, if their is 4, you need to check the one on the right, closest the driver side. if their are 7 check the top left.
Hook your DVOM (multimeter) up, negative to the battery, positive to the bolthead, be very careful not to touch the case with the energized probe, you will kill the FICM.
Have your assistant turn the key on, engine off, check the voltage you should see at least 47 volts. crank the engine, you should see at least 47 volts. if the truck starts you should see 47 volts while the truck is running. if the truck wont start spray a little ether into the air filter and try again, with the truck running you should see 47 volts at least, if not, you need a new FICM, case closed.