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Discussion Starter #1
have a 2003 f350 that I installed a 2004 6.0 in Has been running great with no issues for 8000 miles ,always starts easy even in the cold weather , no coolant loss .I added arp head studs and egr delete .No lack of power or hard starting until last week it just quit like the key was turned off .I have auto enginuity and the hi pressure oil pressure is holding at 45 when the key is off ,during cranking the pressure is only showing 175 lbs .Will a hpop get weak all at once or should i look at a o ring somewhere first ?second question is WHY DID FORD PUT THE ENGINE SO FAR BACK?
 

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Pressure shoulbe be close to 0psi KOEO, Needs to be 500+ to start.

03-04 6.0l have common issues with pump failures. It may not be that serious though. Suspect icp and ipr first. If you dont have the proper tools to diag correctly, throwing parts at it will get very expensive quickly.
Unplug the icp sensor on the pump and see if it will start.
 

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Discussion Starter #3
I think I have the proper diagnostic equipment ,I purchased the auto enginuity and have it hooked up .My oil pressure never goes to 0 it always stays at 48 until i crank it then i see 175lbs but never any higher.I pulled the wire from icp and still nothing .I also put my thumb over the icp hole and it never builds enough pressure to blow my thumb off , I have plenty of extra known good parts to use but I have never chased down a hpop problem .I hate to tear down the wrong part of engine guessing .Shouldnt i see enough pressure to push my finger away from the oil while its cranking .I have an early 04 engine thanks
 

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"resident smarty pants"
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If your ICP is on the passenger valve cover, then the air pressure test is not that hard.

Do you have an extra IPR connector?
 

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PROCEDURE TO PRESSURE CHECK THE HPO SYSTEM W/ SHOP AIR (100 psig):

See the video below starting about at 6:00 minutes.
mms://multimedia.ford.com/seopts/Tech_3_256klarge.wmv
(paste URL in browser)

One way to diagnose for an HPOP leak without a teardown: Remove the ICP sensor --- use this hole to pressurize the HPO system with 100 psig air (05-07 the ICP is on the passenger side valve cover). You should use an M12x1.5 to a #4JIC fitting . You also need to have a way to send 12V power to the IPR, but only for 30 seconds or it will burn out.

You should be able to remove the IPR harness without removing the turbo.

Remove the coolant reservoir and take the FICM and bracket off and remove the last intake bolt (and possibly the last valve cover bolt on the top edge) so you can get your hand back and unplug the IPR. Be VERY careful w/ the FICM connectors!

To command the valve - you can use an old ipr connector from an old harness wired to a cig. lighter plug and only keep it plugged in for 30 seconds not to damage the ipr. Try asking a tech at your local ford dealer, maybe one will be nice enough to snip one off a harness thats laying around. Red wire switched power Pin A B+; Yellow /red switched ground Pin B-.

Remove the oil fill cap, remove the CCV hose that goes into the air intake from the other valve cover, take a piece of heater hose and listen in BOTH spots after applying shop air to the ICP fitting. It will take a minute to push the oil out of the oil rail before you are able to hear the air flow (note the air will flow because the IPR valve is still open). As soon as you hear the air flow, command the IPR valve to close (ONLY for 30 seconds). If you hear air coming from either one of the spots you are listening to, then it's probably a leak in one of the oil rails. If you hear air coming from BOTH sides it's probably the HPOP or STC fitting. Note - when the IPR is commanded closed, you should here a slight "POP" sound.
Also:
If IPR is at 80% while at hot idle, then you have high pressure oil leak, failed pump or a bad ipr valve.
IPR should be around 22-24% at hot idle; up to maybe 30% but that maybe a little too high.

There is a hole that is situated just above the HPOP drive gear. If air is heard/felt exiting this hole when air testing, this is normal if IPR duty cycle is not commanded to 100% because that is the exhaust passage. The way to condemn a high pressure oil pump is to air test it with the turbo oil supply tube removed from the top of the oil cooler base. If air is heard/felt from this port during air testing, the high pressure oil pump is bad.
 

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mms://multimedia.ford.com/fordstar/66920.wmv
(paste URL in browser)

content:
6.4L stuff for 28:40 minutes
28:40 - fuel in coolant diagnostics (two reasons: bad injector cup OR cracked head)
35:45 - HPO system updated components
40:00 HPO diagnostics
42:00 - locations of common HPO leaks
44:35 - Fuel flow pressure tester
55:55 Q&A w/ techs
1:10:43 - discussion of HPO system and IPR screen debris and IPR diagnostics
1:46:55 - discussion on a cracked cup and a cracked bore (head)
2:00 - discussion on problems with aftermarket oil filters"
 

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"resident smarty pants"
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Stock truck:

IPR:
IPR should be around 10% - 15% DC @KOEO
IPR should be around 84% DC when cranking. I believe as high as 1900 psig
IPR should be 22-24% at hot idle (MAYBE as high as 30%)

ICPv:
0.15 - 0.35v (typical is 0.19-.24v) KOEO, no pressure registering on my HPO gauge
0.19 to 0.9v cranking - as high as 1900 psig though
0.80-0.85v at hot idle - around 500 - 580 psig (anything over a volt, then it is time to start looking).

The IPR (injection control pressure regulator) is duty cycled by the PCM. One side of the two wire connector should have B+ on it and should be load tested rather than using a voltmeter as the pinpoint test is likely to suggest. You can use an ohmeter to test continuity through the IPR itself (should be between 3 and 15 ohms) but a better test would be to feed it B+ and a known good ground and feel/listen for the click. I believe it is rare for these to fail electrically.

If IPR is at 80% while at hot idle, then you have high pressure oil leak, failed pump or a bad ipr valve.
 

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"resident smarty pants"
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"resident smarty pants"
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The tests I described can usually pinpoint a failed IPR valve.
 

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Discussion Starter #14
pressurized the oil system and could hear and feel air from both sides so i removed the oil pump cover. I wanted to see exactly where the leak is at ,I tested with 100 lbs but cant see a leak any where .I checked around the stc fitting but didnt see or hear anything .Any suggestions
 

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"resident smarty pants"
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Did you command the IPR closed?
 

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Discussion Starter #16
i powered it for a few seconds while adding air before i removed the oil pump cover,now i added air and plugged the oil line while looking for a leak but havent been able to find it
 
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