IPR Removal - PowerStrokeNation : Ford Powerstroke Diesel Forum
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post #1 of 3 (permalink) Old 04-06-2010, 03:24 AM Thread Starter
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GilroyRacing's Avatar
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Location: Nanjemoy, Md
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IPR Removal

I ordered a IPR O-Ring Kit.

I pulled the fuel bowl to replace some bad O-rings.
While I am at it I want to replace the IPR o-rings as well.

Can someone walk me trough this, or show me a write up or location of the IPR?

Thanks for any and all help.

96FordF3507.3PSDCC, (Line X'd) bed, 4x4, 5 speed manual, 4.11 gears, 285/75/16 Cooper Discoverer ATP , 260,000 miles, 3-4" down pipe, 4" exhaust w/5" polished SS tip, gutted EBPV, chrome nerf bars, autometer ultra lite pyro and boost gauges, alpine cd player, alpine speakers, Garmin GPS.
"Real trucks have 3 Pedals, 2 Sticks, and No Spark Plugs"
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post #2 of 3 (permalink) Old 04-06-2010, 05:13 AM
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Re: IPR Removal

If you've got the fuel bowl removed you are almost home! The IPR is screwed into the bottom of the HPOP. You unclipped the two-wire connector to the IPR when you undid the fuel bowl wiring harness and took out the bowl. Suck the oil out of the HPOP reservoir (using a mightyvac or similar) or get lots of rags to soak up the oil that will flow into the valley. Remove the sheetmetal nut on the end of the IPR and slide the coil off the IPR body. Use a 1-1/8" deepwell socket to remove the IPR body. Check out the old o-rings for damage and note their locations. Replace the o-rings and then reinstall the IPR body. Then reinstall the coil and sheetmetal nut. Here's an old writeup by Coach Davis back in the old days of TDS (guys that have been around for awhile will remember him):

Injection Pressure Regulator Removal and Replacement

by Coach Davis
I've been having a slight problem with my truck not wanting to idle very smooth especially when hot and the more miles the oil gets on it, the worse it would idle. With the engine cold it would idle pretty smooth, but hot, it had somewhat of a shake to it. When I purchased this truck, the oil had been in a little too long on this ONE and only ONE oil change and because the HEUI system is so sensitive to clean oil that I probably was going to have to change some of the components to remedy the idle/flutter problem.

I purchased a new IPR a few months ago and was trying to get enough miles on the oil before I changed it so I could ensure some of the characteristics that changed were not because of "NEW" oil. New oil will always make a Powerstroke run a little better than oil that has 3000 miles on it. I wanted to make sure I installed the IPR with the 3000 mile oil.

The Procedure:

I removed the plug on the top of the high pressure oil reservoir and took my tried and true turkey baister (equipped with a rubber fuel line and then steel brake line attached to the rubber fuel line so I could get through the small hole and go to the bottom of the reservoir to extract ALL the oil), and proceeded to extract all the oil out of the reservoir which took some time, but ended up getting a full quart out of it. Draining this HP reservoir really saved a big time mess!!

Next I drained my fuel filter bowl and loosened the lid to ensure all the diesel would be able to drain, then removed my intake "Y", stuffed shop rags in the ports and proceeded to loosen all the hoses and wiring harness associated with the fuel filter housing/IPR. I then removed the two bolts holding the fuel filter housing on the engine and lifted the housing up and out of the valley of the engine.

I then removed the cheap nut holding the IPR solenoid on and slid the solenoid off. I then took a deep socket and slowly removed the IPR.

I then cleaned around where the IPR was with a lint free cloth to ensure the new o-ring wouldn't be damaged by dirt/trash upon seating. I then coated the NEW IPR o-rings etc. with new engine oil and replaced it back into its respected provision. I then reinstalled the IPR solenoid and tightened the cheap nut ensuring I had the wiring harness connector turned in the correct direction.

I then took carburetor cleaner and sprayed the valley where a little diesel and a small amount of oil had spilled. I cleaned the entire valley and then reinstalled everything previously removed.

I then took a small funnel and poured exactly 1 quart of new oil back into the HP oil reservoir and re-installed the plug.

After the engine turned over a few more times than usual it cranked. After warming the engine up, I then proceeded to the highway where I ran locked out of OD for about 5 miles at 3200 rpm's to eliminate all the air from the HP oil system.

After returning home I immediately noticed the idle was more stable and after putting 100 or so miles on since the change, I can definitely tell a difference in the performance and idle characteristics of the engine. I used to have what I call a missing cylinder flutter sound and that has for the most part been eliminated so far. The truck also runs somewhat easier going down the highway and the cranking time which was actually normal before, is very quick now, even on initial startup in the morning. I was surprised by this because the truck actually cranked normally with no long cranking time hot or cold. I'm also interested to see if fuel mileage will fluctuate some and I'll post when and if it does indeed increase.

I wanted to post this information for some of you that are experiencing some of the characteristics my truck has been having. I'm also going to replace the ICP when I find a good price on one, but I do my truck as I do my race car and change ONE thing at a time so I'll know what the part actually did and IF it actually changed anything. Then I can go to the next step and change something else.


97 F250 SC 4x4, E4OD, 4.10 LS, Basically Stock, Relocated Block Heater Plug, Ext Trans Filter, Tru-Cool Max, I/C Mounted but not Plumbed

SOLD: 94 F350 CC DRW PSD, 5 Speed, 4.10 LS, SBC Con-O, Baldwin Filter, Tymar HPX Hose, 3 DP, Bilsteins, $12 AIC, Coolant Filter, Explorer O/H Console, Trans Temp, Boost, and Pyro, Pedestal Mod, Gutted EBPV

Last edited by Patrick Feeley; 04-06-2010 at 05:20 AM. Reason: Added Coach Davis' writeup
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post #3 of 3 (permalink) Old 04-06-2010, 09:19 PM
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Re: IPR Removal

Make sure you suck as much oil out of the HPOP res. Otherwise you will get it all in the valley when you pull the ipr.

1997 F-250 PSD, 130k, 4x4, Outlaw E4ODX, Standard Cab, reg bed, 3.55 LS rear, Swamps 225/146 injectors, Autometer Guages Pyro/Boost/Tranny, 3" downpipe, 3.5" adjusted exhaust, ts 6 pos chip, Tonys fun programs, Tru-Cool H7B, 285/75, factory alum rims, Western V-Plow, 6.0 intercooler installed not plumbed

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