Ford 6.0L Power Stroke Diesel :: Truck Died And Refused To Start - Code P0603


Jul 2, 2015

So I have been fighting an electrical issue off and on since I bought the Excursion and I am at my wits end!

Put in 2 injectors. 1 in November and 1 last week. Thinking that it would fix my P0603 and the missing issue I was having. Plus the truck tossed a code for #4 and #5 injector. According to a snap on scanner and my AE the injectors were bad. The missing issues are gone, but I keep getting a p0603.

Go back to the middle of May. Truck died and refused to start. I put a fuel pump in it due to lack of fuel at one point thru the no starts. Shop had it 2 weeks and replaced the Cam sensor. Truck has been spot on for the last month zero issues.

Fast forward to today! Hooked up the trailer and loaded my tow tune. Check codes before hand and have a P132b code. Look it up and is a multitude of things to check. Clear code, tune the truck and head out for the weekend. Sat in traffic for 95 minutes to go 13 miles to the highway I needed to get to.

Driving the truck I had zero issues, until I got off the exit ramp to the campground. During the 2 hour drive I monitored a few pids on the scan gauge to see how things were on the truck after the work. The following are driving down the road at 2k RPMS 70 MPH give or take 5 MPH.

boost 7.3
map 22.9
EOT 225
FWT 211
TFT 163
CPM .28
ICV 1.9
VGT 57
IPR 37.3
CVI 4-5 (fluctuates)
SYNCH went to 0 when it died.

Truck shuts off and restarts right away and keeps running. I get to the campground and hook up the tuner to the truck and I have 2 different codes. My buddy the KAM P0603 and a new one Crankshaft sensor Pos A/ I can not remember what the code # was.

So after dropping 1500.00 on the truck the last 2 months, I am at a loss. The shop I took it to was a new place for me and I was not impressed. The lack of communication, 3 scratches on the truck and saying the truck had a miss and they didn't look at the injectors at all.

The 2 options I have are 45 miles away or 100 miles away. After today I believe it is an electrical issue and would rather spend a weekend of my time trying to find it. Where are the known chaffing points on the 03' 6.0L.

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My wife was driving through the intersection when the truck died... Tried to start it again but no go, I had it towed home, and stared to troubleshoot.

I have a Scan gauge2 and these were the readings: FMP: 47.5, IPR: 84.71, SYC: 1, ICP: 0

I pulled the IPR (that was only a year old) and the screen was perfect. I had 11.5v at the plug for the IPR, and on the Ohms scale I was reading 1.8Mohms.
I went to the dealer and got a new IPR, and still no start. and the only change in the reading on the scan gauge was the ICP is now reading 56. The gauge on the dash is reading normal oil pressure, but I haven't checked actual Low-end oil pressure.

Last month I replace the HPOP, and 1 faulty injector. Now I thinking wire loom, defective new IPR from the dealership or the new HPOP has failed.

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The next day it threw a P0284 – Cylinder #8 contribution/balance, and was clearly missing on a cylinder. Despite the lack of a puff of smoke at start-up, I was pretty sure it was an injector. So I ordered one from White Bear Lake, and a fuel pressure test adapter from Strictly Diesel. Then I decided to do some testing with AutoEnginuity. Tried the injector buzz test first and got a note that the truck was not capable of performing the test. Tried starting truck and gauges swept and wouldn’t turn over. Tested batteries again: main battery 11volts, aux 12volts.

I got the batteries in and the stupid thing runs like new. Only codes are P1000 and P0603. Truck passed the injector buzz test, and cylinder contribution test graph is almost a flat line.

Take-aways:
1. Bad batteries can cause all sorts of havoc.
2. Always use a voltmeter that displays tenths of a volt, because if it’s only showing whole volts, it could be rounding up. The 12 volts from my first test was probably more like 11.6 volts.
3. Always do as much testing as possible before buying parts.
4. Costco does not sell Kirkland batteries anymore. They only stock Interstate, and the Interstate warranty has dropped from 36 months free replacement to 30 months.
5. The Walmart and Autozone batteries with the five year free replacement are “out of stock” and I’m guessing they won’t be back with Interstate dropping their replacement dates.
6. Most of the car batteries in the US are made by Johnson Controls.
7. Motorcraft batteries did not get very good reviews.
8. Interstate said that AGM (absorbed glass mat) batteries stand-up better to the additional vibration and heat experienced under the hood of a diesel, but they are significantly more expensive, and not all the brands offer an AGM with a better warranty than their best lead-acid offering. Also, the guy at Sears said AGMs are only beneficial for newer cars that continue performing electronic functions after the ignition is turned off. He said he’s seen lead-acid batteries outlast AGMs, but didn’t specify if those were out of diesels or not.

Questions:
1. Can I expect the P0603 to go away after the drive cycle is complete?
2. What should I do with the new injector? If I return it there’s probably a restocking fee. If I wait for a complete injector failure I don’t get the core charge back until then. With the FICM compensation, I don’t know of any way to identify weak injectors without IDS.

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Checked so far

Batteries checked and both are good
No mods done to it
New ICP sensor and pigtail
New water pump
New injectors 20k miles ago
Oil changed 1100 miles ago
New filters upper sad lower

2003 Ford F-250 King Ranch 6.0

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