How Can I Diagnose And Repair A Faulty Fuel Injection Control Module On A 6.7L Power Stroke Diesel Engine, Specifically When The Engine Is Experiencing Intermittent Loss Of Power And A Low Fuel Pressure Error Code, While Also Considering The Impact Of The Truck's Recent Upgrade To A High-flow Air Intake System And Performance Chip?

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To address the issues with your 6.7L Power Stroke diesel engine, follow this structured approach:

  1. Understand the FICM's Role: The Fuel Injection Control Module (FICM) manages fuel injection, monitors pressure, and ensures proper fuel delivery. A faulty FICM can cause low fuel pressure and power loss.

  2. Check Fuel Pressure: Use a fuel pressure test kit to measure pressure at the test port near the fuel rail. Ensure it's within the recommended 50-60 psi range. Low pressure could indicate issues with the sensor, FICM, or fuel system.

  3. Inspect Recent Upgrades: The high-flow air intake might be introducing debris, potentially clogging fuel injectors or filters. Check and replace the fuel filter if necessary. The performance chip might be increasing fuel demand beyond stock capacity, stressing the FICM.

  4. Scan for Trouble Codes: Use a code reader to retrieve all codes, focusing on those related to FICM (e.g., P0190). This helps identify if the FICM is faulty or if other components are involved.

  5. Inspect FICM and Wiring: Locate the FICM on the driver's side and check wiring and connections for damage or corrosion. Ensure fuses and relays are functional.

  6. Test FICM Voltage and Injector Signal: Use a multimeter to check the FICM's power and ground circuits. Test injector circuits for proper resistance and signal from the FICM.

  7. Consider FICM Replacement: If tests indicate FICM failure, replace it. Ensure it's the actual issue by ruling out other causes. Consider software updates or reflashing, especially with the performance chip.

  8. Post-Repair Testing: After repairs, clear codes and test drive the truck. If issues persist, adjust or remove upgrades and consider a custom tune.

  9. Seek Professional Help if Needed: If unsure, consult a diesel specialist for assistance.

By systematically checking each component and considering the impact of upgrades, you can isolate and address the issue effectively.