Some 2003-2007 Ford F-Super Duty, 2003-2005 Excursion and 2004-2010 E-Series vehicles equipped with the 6.0L engine may exhibit rough running, lack of power, hard start or no-start concern, with or without DTC P0611 or various injector circuit codes. This concern may be caused by a DC-DC converter located in one half of the Fuel Injector Control Module (FICM) or by the main circuit board in the other half of the FICM.
The FICM contains two major internal components, the main circuit board and a DC-DC converter. The DC-DC converter is the device that amplifies battery voltage to 48 volts to operate the injector.
Low FICM supply voltage results in increased FICM operating loads, potentially damaging or shortening the life of the FICM.
For contribution codes without circuit codes, go to Powertrain Controls/Emissions Diagnosis (PC/ED) pinpoint test P. Otherwise, follow this procedure….
1. Connect Integrated Diagnostic System (IDS) scan tool and confirm that battery voltage is greater than 11.5 V (key on/engine off). If battery voltage is less than 11.5 V, do not continue with this procedure. Refer to Workshop Manual, Section 414-00. If battery voltage is 11.5 V or higher, continue to Step 2.
2. Remove the FICM relay.
3. Perform a programmable module installation on the FICM to correct possible corrupt FICM memory. IDS scan tool software must be at release level 65.18 or higher. Select module programming on the IDS menu screen. Select PMI and click on the tick button at the bottom right corner of the screen. Follow the screen directions until it states to install the new module. At this point, click on the tick button again and continue to follow the on-screen directions to complete the PMI procedure.
4. Reinstall the FICM relay.
5. Monitor the FICM_M power parameter identification (PID). Disconnect the glow plug module (GPCM) VPWR circuit to isolate the GPCM and alternator from the FICM and provide more consistent FICM testing. Disconnect the fuel heater relay, if equipped. With IDS already installed, turn the ignition to the RUN position.
6. Monitor engine oil temperature (EOT) PID. If EOT reads 32 degrees F or less, proceed to Step 11. If EOT reads greater than 32 degrees F, proceed to Step 7.
7. Turn the ignition off.
8. Disconnect the EOT sensor.
9. Using Rotunda Technician Tool Program Universal Gauge and Component Tester (OTC3385) or equivalent, adjust the setting to 100,000 ohms resistance. Verify tester resistance using a digital volt ohmmeter (DVOM) with 10 mega ohm minimum impedance.
10. Connect the instrument gauge system tester between the EOT signal and SIGRTN circuits at the harness side of the EOT connector. Failure to apply exactly 100,000 ohms of resistance at this location may result in inaccurate test results.
11. With the key on and engine off, monitor the FICM_MPWR PID and record the value.
12. Cycle the ignition to off and back to the run position to activate the injector pre-cycle. Monitor the FICM_MPWR PID and ensure that the voltage reading is greater than 45 V during the entire duration of the last 10 seconds of the fuel injectors clicking. If FICM_M power is 45 V or greater, the PMI repaired the concern. Reassemble the EOT circuits if previously removed. Return the vehicle to the customer. If FICM_MPWR drops below 45 V during pre-cycle, reassemble the EOT circuits and proceed to FICM Half Shell Replacement procedure.
FICM HALF SHELL REPLACEMENT
Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. Use extreme care when performing this repair.
1. Remove the FICM from the vehicle and clean off any debris using shop air.
2. Remove the two Torx T20 retaining screws and inspection plate from the back of the FICM.
3. Inspect the buss connector screws. If FICM is an early style with seven connector screws, do not reassemble. Replace the FICM assembly. If the FICM features four screws, proceed to Step 4 for inspection and repair.
4. Remove the four Torx T10 buss post retaining screws. When removing the screws from the FICM, you may find metallic shavings. Be sure to clean any debris from the screws before reinstalling.
5. Remove the eight Torx T20 half shell retaining screws.
6. Carefully separate the top and bottom half shells of the FICM. The upper half (with the three main FICM harness connectors) contains the main circuit board. The lower half contains the DC-DC board. They are sealed by a molded perimeter gasket. Gentle prying may be required to separate. Retain the gasket for reuse.
7. Inspect the main circuit board for burning and/or damaged components. If any evidence of loose or burned components is found, replace the FICM assembly. If no evidence of loose or burned components is found, proceed to Step 8.
8. Install the original half shell gasket that was removed in Step 6 in the new lower FICM half shell. Before putting the two FICM half shells together, be sure to clean any dust or debris using compressed air.
9. Assemble the upper and lower FICM half shells. Install eight case screws and torque to 18 in.-lbs. (2 Nm).
10. Install the four buss screws removed in Step 4 and torque to 9 in.-lbs. (1 Nm).
11. Install the inspection plate, seal and retaining screws and torque to 18 in.-lbs. (2 Nm).
12. Install four replacement mounting grommets.
13. Install the FICM and clear all DTCs.