04-18-6 Driveability - No Start Or Constant Engine Misfire - Fuel Injection Control M - Diesel Truck Forum - TheDieselGarage.com
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04-18-6 Driveability - No Start Or Constant Engine Misfire - Fuel Injection Control M

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04-18-6 DRIVEABILITY - NO START OR CONSTANT ENGINE MISFIRE - FUEL INJECTION CONTROL MODULE (FICM) DIAGNOSIS - 6.0L DIESEL

Publication Date: August 31, 2004

FORD: 2003-2004 EXCURSION, F-SUPER DUTY


This article supersedes TSB 04-11-5 to update the vehicle lines listed in the printed version of TSB 04-11-5.

ISSUE:
Vehicles equipped with a 6.0L engine may exhibit a no start or a constant engine misfire. Multiple root causes can create these symptoms, including the fuel injection control module (FICM).

ACTION:
If the FICM is suspected to be the root cause refer to the following procedure to verify the FICM is at fault before replacement.

SERVICE PROCEDURE

NOTE: VERIFY THAT THE WDS IS AT THE LATEST RELEASE LEVEL AND THE VEHICLE IS UPDATED TO THE LATEST CALIBRATION. CALIBRATION ISSUES AND RELATED POWERTRAIN COMPONENTS CAN MIMIC A DEFECTIVE FICM.



NOTE: THE MOST COMMON SYMPTOMS OF A FAILED FICM ARE A NO START OR A CONSTANT MISFIRE AT ALL ENGINE TEMPERATURES. DIAGNOSTIC TROUBLE CODES (DTCS) U0105 OR P0611 MAY ALSO BE PRESENT. SYMPTOMS OTHER THAN THESE ARE NOT LIKELY TO BE CAUSED BY THE FICM MODULE.



NOTE: THE REPLACEMENT FICM DOES NOT CONTAIN SOFTWARE, IT MUST BE PROGRAMMED PRIOR TO USE.



Check for FICM wiring harness chafing and use a wiggle test to verify integrity of connections at the FICM and injectors. It is common to see DTC's P2614 and P2617 as a result of wire chafing. It is often necessary to push on the engine/injector harness to duplicate a ground out condition. Ensure FICM connectors are fully seated. If any wire chafing is noted, repair as necessary and reevaluate vehicle, if the condition is corrected return vehicle to customer. If no wiring chafes are located proceed to Step 2.
NOTE: SOME COMMON CHAFING LOCATIONS ARE: UPPER LEFT VALVE COVER, VALVE COVER BOLT, AND INTAKE BOLTS, UNDER AND NEAR THE FICM.



Set up WDS to test FICM power and grounds by selecting:
Tool Box
Datalogger
Tick Mark
Powertrain
Engine
Tick Mark
Clear All PIDS
Select:
FICM_LPWR
FICM_MPWR
FICM_VPWR
B+
KOEO
Tick Mark
Monitor datalogger PIDS for the following values:
FICM_VPWR: FICM vehicle power from ignition switch voltage = battery voltage
FICM_ LPWR: FICM logic power from fuse, FICM relay voltage = battery voltage
FICM_MPWR: Internal FICM power voltage = 47-50 volts
If all of the above readings are within range, proceed to Step 4.
If any of the above are out of range, disconnect the three (3) FICM connectors and inspect condition of connector, pins, and wiring at the connector, paying close attention for wiring chafes. Repair any issues and reevaluate vehicle, if the condition is corrected return vehicle to customer. If the condition is still present continue to Step c.
With a voltmeter check the following:
Check for B+ voltage at pin 27 of connector 1388c with the KOEO. If no, or low voltage is present, repair as necessary. If B+ is present, jumper pin 27 of connector 1388c to a good battery ground (see Figure 2 at end of article).
Check for B+ voltage at pins 4,7,8,23,24,25 (see Figure 2 at end of article). If no or low voltage is found at any pin, repair as necessary. If B+ is present at all pins, replace the FICM and return vehicle to customer.
NOTE: THE REPLACEMENT FICM DOES NOT CONTAIN SOFTWARE, IT MUST BE PROGRAMMED PRIOR TO USE.



Set up WDS for injector electrical self test by selecting:
Tool Box
Self Test
Tick Mark
Powertrain
Engine KOEO Injector Electrical Self Test
Tick Mark
Follow Screen, Tick Mark
Perform Injector Electrical Self Test (Buzz/Click Test) this tests the wiring from the FICM to each injector.
First all eight (8) injectors will click. Then listen to each injector individually in numeric order 1 thru 8.
NOTE: EACH CLICK IS SEPARATED BY APPROXIMATELY TWO (2) SECONDS. LISTEN FOR ANY INJECTOR THAT DOES NOT CLICK.



NOTE: IF ALL INJECTORS CLICK, CONCERN IS NOT FICM RELATED, PROCEED WITH NORMAL PC/ED DIAGNOSTICS, INCLUDING CAM SENSOR AND CRANK SENSOR INPUTS FOR FICM SYNCHRONIZATION.



If any injector does not click then proceed to check the wiring from the FICM to the particular injector that did not click.
Using a test light, probe between pins 1 and 2 of the injector connector harness side (Figure 1). Start the engine and monitor the test light for indication the FICM driver is functioning (test light flickering).
Repeat test light probe between pins 3 and 4 of the injector connector harness side.


Figure 1 - Article 04-18-6


NOTE: IF ENGINE WILL NOT RUN, RERUN THE INJECTOR ELECTRICAL SELF TEST WHILE MONITORING THE TEST LIGHT. THIS WILL MOMENTARILY ENERGIZE THE FICM DRIVERS.



If the test light does not illuminate for a particular injector, check harness integrity and repair as necessary.
If the harness is OK, replace the FICM.
NOTE: THE REPLACEMENT FICM DOES NOT CONTAIN SOFTWARE, IT MUST BE PROGRAMMED PRIOR TO USE.




PART NUMBER PART NAME
4C3Z-12B599-AARM FICM


WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage

DEALER CODING
BASIC PART NO. CONDITION CODE
12B599 42



Figure 2 - Article 04-18-6


--------------------------------------------------------------------------------

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.

Copyright 2004 Ford Motor Company

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