[Dannie1234]

Need some help desperately. I have a 2003 f350 with the 6.0 in it. I was having issues with it and found that the stand pipes and lines were bad. The truck then started but ran like trash. Tested Everything and it would only have 1500psi wot. So I decided I was done playing games I installed a new hpop, ipr, ipc (both with new pig tails.) cleaned everything really good. Now the truck cranks but won’t start. Gets up to 85% while cranking. When the icp is plugged in it reads 10psi while waiting once cranking it only goes to 280 to 320. Definitely not enough pressure to fire it. When I unplugged the icp still no start. Could I have wired the icp pigtail wrong. Did one wire at a time following off the old icp. What could it be. Since it still don’t start with the icp unplugged. Possible pcm maybe. Please help. Need this for Monday for work

 

[Dannie1234]

Also side note the icp voltage is like .2 to .4

 

[cfherrman]

Did you crank enough to bleed the air out? It takes a lot of cranking.

What brand of parts?

 

[bismic1]

Did you crank enough to bleed the air out? It takes a lot of cranking.

What brand of parts?

Well the OP was on 3 hours ago, but no response to the questions. Oh well ..............

"Please help" statements should mean that we don't have to post "Please respond"!

(well intentioned "prodding").

Also, I wish I had a nickel for every post about possibly changing out the PCM! Hopefully the OP isn't spending that money yet, they just do not go out very often!

 

[Dannie1234]

Did you crank enough to bleed the air out? It takes a lot of cranking.

What brand of parts?

I did 6 30 second cranks with the yellow wire. Then 2 more times with the key. All motor craft parts

 

[Dannie1234]

Well the OP was on 3 hours ago, but no response to the questions. Oh well ..............

"Please help" statements should mean that we don't have to post "Please respond"!

(well intentioned "prodding").

Also, I wish I had a nickel for every post about possibly changing out the PCM! Hopefully the OP isn't spending that money yet, they just do not go out very often!

I apologize I didn’t hit the post reply button But it’s there now. But so you know I cranked it 6 times for 30 seconds each time with the yellow wire and then twice with the key. And they are all motorcraft parts

 

[bismic1]

If you wired the ICP pigtail wrong (as the ONLY issue), then it should have started when you had the sensor unplugged. Issues only happen with the pigtail and/or connector when you have insulation missing and wires rubbing......or when it is plugged in.

Hopefully your issue is the IPR valve (assuming no leaks now). That is what I would pull and inspect next.

If not that, and no leaks, then the HPOP is suspect. Those early HPOPs don't have the best reliability record unfortunately.

 

[Dannie1234]

If you wired the ICP pigtail wrong (as the ONLY issue), then it should have started when you had the sensor unplugged. Issues only happen with the pigtail and/or connector when you have insulation missing and wires rubbing......or when it is plugged in.

Hopefully your issue is the IPR valve (assuming no leaks now). That is what I would pull and inspect next.

If not that, and no leaks, then the HPOP is suspect. Those early HPOPs don't have the best reliability record unfortunately.

I’m getting ready to do an air test on it now. You think it’s a bad hpop even though it’s new

 

[bismic1]

I hope not. There have been multiple cases of bad OEM (and aftermarket) HPOPs out of the box (for the 03-04 model year). That said, it is my opinion that Ford FINALLY took notice of it and had their re-manufacturer address the known issues. Just to be factual, there is absolutely nothing available (no documentation or proof) to confirm that theory - not that I have found anyway. I guess I have to just say that I HOPE that Ford has taken notice and addressed the issues. The failure modes have been documented!!

The best way to air test is through the IPR port if you have the adapter to do so.

SWAG PERFORMANCE 6.0L IPR AIR TEST TOOL FITTING

SWAG PERFORMANCE FORD 6.0L POWERSTROKE DIESEL IPR AIR TEST TOOL FITTING

swagperformanceparts.com

Also, if you use this fitting, you will have the IPR out so that it can be inspected. It's operation can also be checked "fairly" easily on the bench.

To air test from the ICP sensor requires commanding the IPR closed, if you didn't already know that.

 

[bismic1]

One thing to add, you stated that the parts were OEM, but that is only part of the concern. There are SO MANY counterfeit parts on the market, could you tell us WHERE you bought the parts (especially the HPOP and the IPR)?

 

[Dannie1234]

The Ipr is right from the dealer the hpop is from diesel source. I just pulled the Ipr and it came out in two pieces the other part is still in the truck guess I gotta pull everything off again to get it out

 

[bismic1]

Ouch!

Actually they were built so that you COULD do that, but they never SHOULD do that unintentionally!

 

[bismic1]

Do you have the special IPR socket for installation and removal? You probably do, but I have to ask after being surprised in a few threads over the years.

 

[Dannie1234]

Do you have the special IPR socket for installation and removal? You probably do, but I have to ask after being surprised in a few threads over the years.

yes I do. That’s what I used on it. Between this truck and my 7.3. I’m sitting on two broke down work trucks. Ugh. The only diesel shop within 50 miles of me said it would be a minimum of $600 just to look at the truck.

 

[bismic1]

I hear you! Stick it out here. We have a good track record helping folks, and very willing to do so.

If you can get the other piece of the IPR out without damaging the threads, you should be able to reuse the valve. The o-ring is what seals it.

I would bench test its operation though.

12V power applied to it for very long MIGHT damage the electronics, but 12V on it will close it and can be left on indefinitely. Then all you need to do is rig up the hose to supply air.

I have a few links describing it I think.

 

[Dannie1234]

I’m definitely gonna stick it out. I love these trucks. I’m done for the night. One last thing for today. Do you have any idea on how I would get the other half out without pulling the turbo and all that to get the hpop cover off

 

[bismic1]

I don't recall the thread size/configuration. I knew it at one time - sorry. If you could get fittings at a local hardware store, take the top works there and see if you can get a pipe coupling with the same threads, screw it on and pull it out. It is only an o-ring holding it in. I have a spare IPR. If I can find some time, I'll try to identify the threads (assuming I don't find the documentation). I'll post up what I can find (if I am successful).

I love these trucks too. After a fair amount of preventative maintenance work, mine is a joy and very reliable. Takes a bit of money and knowledge, but they can be great.

 

[bismic1]

One last thing - the o-rings do the sealing, so ABSOLUTELY no need to tighten the IPR valve all that much when installing. Could this have caused your issue?

 

[Dannie1234]

I don't recall the thread size/configuration. I knew it at one time - sorry. If you could get fittings at a local hardware store, take the top works there and see if you can get a pipe coupling with the same threads, screw it on and pull it out. It is only an o-ring holding it in. I have a spare IPR. If I can find some time, I'll try to identify the threads (assuming I don't find the documentation). I'll post up what I can find (if I am successful).

I love these trucks too. After a fair amount of preventative maintenance work, mine is a joy and very reliable. Takes a bit of money and knowledge, but they can be great.

 

[Dannie1234]

Thank you for all the help. Just so I’m clear I could’ve just tightened the Ipr to much and that would cause the pressure issue