Text Box: Ford 6.0L Diesel
Fuel Injection Control Module “FICM”
Repair / Upgrades
Produced 2003 to 2007 F250 F350 F450 F550 F650 F750 Excursion and E Series to 2009

Description of Failure Modes

If your 6.0 will not start one or more issues are going on, could  be injectors, sensors CKP, CMP, glow plugs, glow plug controller, fuel delivery, engine wiring harness (chaffing & shorting are common), the HPOP (the 6.0 takes 500 lbs of oil pressure to start), internal HP oil leak, or it could be the FICM. If after a long cranking with no start you get a lot of white smoke (raw un-burnt fuel) out the exhaust, the problem is  probably in the injectors or glow plug system. If you do not get any smoke, the problem is probably in the FICM. It is usually accompanied w/ multiple injector codes and a p0611 code.

The 6.0 injector has two solenoids on it; one turns the injector on (open) and the other turns it off (close). Ford came out with a new program referred to as “inductive heating” for the FICM, intended to help alleviate issues with missing and rough running during cold startup due to sticking  spool valves in the injectors (another issue). This program works by exciting the spool valves (the buzz you hear) by running current through their coils in an attempt generate heat and warm them up.

The original programming for the FICM only used the inductive heating when the engine oil temperature (EOT) was less than around 48*F.

The “first” updated heating strategy turned it on any time the EOT was less than 184*F: meaning every time you started the truck (if it had been shut off for more than 10 minutes) the inductive heat was used!

The newest  factory update to the heating strategy has it coming on below 148*F; better, but that's still a lot of current draw.

Unfortunately, there have been some serious consequences. The FICM on the 6.0  basic job is to convert 12 VDC to 48 VDC and deliver this to the injectors at the proper time. Under normal operating conditions, the FICM typically draws 6-7 amps at 12V into the FICM power supply, which is well within its design limits.

With the inductive heating active this current draw increases to 24-32 amps. Although the FICM power supply is capable of sustaining this load for short periods of time it eventually gets very hot.

Manufacturing techniques & quality control issues have further added to the problem, between improperly installed components on the circuit boards (PCB), missing parts—yes missing parts, overall inspection process. It is not a question of if the unit will fail but when it will fail.

The FICM’s 48 volt power supply is actually four separate or independent units producing 5 amps each; if one of the four goes down, the other three can supply enough current to run the truck, even with the inductive heating active. If two of the four go out, the truck may still start and run provided it is warm.

If three of the four go out, the truck will not start or run. If the injector voltage is over 35 volts, they run OK, although not as well as when it is 48 volts. If the voltage drops below around 25 volts, the injectors cannot fire. While most scan tools will display the FICM voltage, they do not 
always show the correct value.

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