I know this may be covered somewhere, but I have exhausted myself researching the Internet to find a solution. I have a 2005 6.0. 250k miles. Truck ran great until EGR Cooler began to leak. I parked the truck for some time before I could fix it. Got ready to perform the repairs and put 2 new batteries in truck and drove it a little. Everything ran great with the exception of it drinking coolant because of the EGR Cooler leaking. Then the truck just died. Wouldn’t restart until it cooled down. Got it home and did the EGR Cooler delete, STC fitting update and oil cooler replacement with Ford gaskets. New oil and oil filter. After getting the air purged, it fired up and idled very smoothly. Went for a test drive and only got about 3 miles and it died. Wouldn’t restart until it cooled off. Got it restarted and watched the ScanGuage 2. IPR was about 30-35%, FICM 48, and ICP in the 800’s. I let it set and idle and started watching the ICP drop. The IPR percentage started increasing. I watched the ICP drop to the 500’s and the it died. No start. Performed an air test through the ICP port and applying 12v power to IPR to command it shut. (No longer than 30 seconds). I determined I had a leak on the passenger side. I pulled the valve cover and did another air test. I could tell most of the air was coming from around injectors 5 & 7. I pulled the rail and did an air test on the rail itself by plugging the nipple cups and no leak. Dummy plugs have already been upgraded (12mm). Standpipes are still 10mm. Yet I still have zero leaks bench testing the rail. I removed all 4 injectors in passenger side. I put them on the nipple cups and did another bench test. I was getting leaks from all 4 injectors. I pulled 1 injector off and plugged the nipple cup, no leak. I poured some oil around nipple cups, stand pipe and dummy plug. No leak. I did see when I first applied air that injector 7 pushed oil out of the 2 ports on tops. I inspected the internal injector o rings and they looked really good. I chose to replace the o rings anyhow. Put all 4 injectors back on nipple cups and did another bench test. Same results. Leaked. I determined (I think) that I’m getting air out of the ports from all 4 injectors. I put it all back together to see if adding oil pressure would reseat everything and seal up. I primed the fuel and oil system and it started up fairly easily. Idled rough. Let it idle and watched the ScanGuage. I noticed that when the oil and water temp reach around 120 or so, I start losing ICP and IPR percentage increases. I let it idle until it died. I let it cool down and restarted. Same symptoms. I decided I try to drive it a little in hopes that the system still had air in it. Stalled again. Hot no start. Now even with it completely cooled off, sitting over night, I get really long cold cranks before it starts. ICP takes a really long time to build. It seems I can keep the truck running by idling up and keeping the ICP up. With doing this the IPR stays around 30%. As soon as I let off the throttle though, ICP drops and now goes right to 85%. I’m at a loss and do t know what to do next. I feel fairly confident that I have a HPOS leak. I’m fairly confident it is coming out of the port holes on top of the injectors. Any thought? Any way to test each injector other than buzz test? Any help is greatly appreciated.

 

Are you sure that the oil rail nipples are straight so that they fit precisely into the injector? Do you lube the top of the injector w/ oil before installing the oil rail?

You may have to bite the bullet and buy new injectors. How many miles on yours?