[carguyz28]

Yes it's a pain, you'll need a certain socket to get it off, or a home made job, easier than with a wrench. Take the degas bottle off, the fick off, and you'll have to get your hand in there. It sucks, there may be an easier way, but that's hiwni do it. Only way I know is by scraping knuckles and swearing a lot. No the turbo does not need to come off, but you can take the tubes off and loosen the turbo and move it aside if you feel it's nessisary.

 

[polish pete]

get the right socket, and unplug the ipr and icp get it out of the way, and remove the icp, its an 1in 1/16th wrench, and get it out from under the truck and it get that way, it works for me.

 

[Michipicoten_SuperDuty]

Alright guys, I ordered a socket. This one:

Fuel Injector Pressure Regulator IPR Socket for Ford Diesel Super Duty 6.0L

I'll report how the process goes. Unfortunately I'm off to Iowa again tomorrow, so it won't be until next weekend.

 

[polish pete]

Alright guys, I ordered a socket. This one:

Fuel Injector Pressure Regulator IPR Socket for Ford Diesel Super Duty 6.0L

I'll report how the process goes. Unfortunately I'm off to Iowa again tomorrow, so it won't be until next weekend.

honestly get the otc one, ive seen even the otc sockets snap, these ipr's that get real old get really stuck so i wouldnt want to see you try to do the job and then the tool breaks.

 

[Michipicoten_SuperDuty]

Well, I already placed the order, so we will see how it fares. I don't doubt that it won't be an easy twist to remove, so I'll just hope for the best.

It won't be a big deal if the job gets delayed again. It isn't my DD anyway.

 

[Michipicoten_SuperDuty]

Well guys, I got to spend last weekend home, and I had time to swap the new IPR in!

It is actually pretty amazing, but with the correct tools it's possible to change the IPR from the top by only removing:

• The surge tank (I just disconnected the two small hoses and moved it out of the way)
• The FICM
• The FICM mounting bracket (take your time with the nuts if they are rusted! I could have easily broken a couple of the studs, but with WD-40 and back and fourth I got 'em)

Thank you guys so much for steering me in the right direction!!! :bowfast::bowfast::bowfast:

The good news:

The truck starts much, much easier when cold. I started it twice at sub-freezing temperatures after sitting for 10-12 hours, and it went on the first try! I didn't even have the block heater plugged in!

Now for the bad news:

While it did start on the first try both times when cold, it still isn't a smooth start. And, sometimes on startup or every time when I floor it for 5-10 seconds, I get the P2290 again. It looks like I've still got some high pressure oil problems to track down.

Where do I go from here? I assume I'm looking at new injector(s) or a new HPOP. How, and where should I start diagnostics? Should I invest in one of these?

6.0L High Pressure Oil System IPR Air Test Tool

Thanks a ton, again.

P.S. The old IPR didn't look too healthy. See pictures. Unfortunately after removal I dropped it and broke off the connector, so I wasn't able to bench test it.

I also posted a picture of the tools I used. They were:

1. 3/8 in. drive breaker bar
2. 3/8 in. drive 8 in. extension
3. 3/8 in. drive stubbby ratchet
4. 3/8 in. drive speciality socket for IPR replacement (the original IPR was in there pretty firmly, but this one held out - not bad for $30, IMHO)

 

[Michipicoten_SuperDuty]

D'oh, I forgot I also used a 3/8 in. drive impact universal joint. It is shown in the picture. I'm not sure how possible it would have been without it.

 

[Michipicoten_SuperDuty]

Yep, I definitely have big injector pressure problems. The truck barely has enough power to go down the expressway, and every time I go up any sort or a significant grade, it throws the P2290.

And, the right front tire blew last night. Literally at 65 MPH went BOOM!

 

[carguyz28]

I'm glad the ipr worked out. I was curious, but couldn't find this thread to ask you. Sucks about the tire tho lol. That's just ####ty luck. As far as I go, I'm not sure where else to lead you. It's hard for me without the data scanner to see what the engine is doing. My code ended with the ipr valve change. The dummy plugs, or stc fittings may need to be updated. Your pump may be weak, or you can have somthing as simple as bad fuel filters. Or a clogged fuel line somewhere. It's hard to say from here.

 

[Michipicoten_SuperDuty]

Thanks for checking back in! I have an Actron CP9580A that is apparently capable of displaying live data (including commanded and actual injector pressure), but it doesn't seem to want to work on this truck. I have been taking it to work every day this week, and it has been starting on the first try, every time. They aren't nice and smooth starts, but it goes on the first try. That's a major improvement from before.

I would love to think it's a fuel supply problem, but I'm not sure. I did just replace the fuel filters and cleaned the fuel conditioning unit less than 5000 miles ago. At least to me, it seems that getting the P2290 every time the engine load is increased really points to a high pressure oil problem. I believe that code is thrown when the commanded injector pressure and actual injector pressure crossed the threshold.

Unless someone has a better idea, this will be my line of action:

I still desperately need to replace the oil cooler. Hopefully very soon I'll have my Ranger back so I can stop driving the big truck every day. I'm going to buy that tool I linked to to test the high pressure oil system with air. As soon as I can take the truck out of service, I'll flush the coolant and pull everything off the top of the engine. At that point, I'll put air to the system and listen for leaks. Hopefully I find something? I certainly hope so at this point.

 

[carguyz28]

If you put air to it you will hear a leak if there is one. Your on the right path man, it's giving that code because the computer wants to see a certain pressure and it's not. Self explanatory code really. The problem is finding where. Could be a lose injector, hpop leak, fuel problem, anything. I wish you were closer, I usually figure these things out in person no problem.

 

[carguyz28]

P2290 P2291 04 6.0 powerstroke no icp, failed hpop pump. tips and tricks on pump removal - YouTube
This guy has some good tips you may want to watch this vid.

 

[Michipicoten_SuperDuty]

That's a helpful video. Thanks for the link!

I ordered the fitting so I can pressure test the high pressure oil system. I'll report back when I have results.

I'm starting to really wish I had something like AutoEngunity or a Scangauge II or (possibly) an AeroForce Interceptor gauge...

In other news, I tried reverse flushing my cooling system yesterday. I came to find my oil cooler is completely clogged. I really need to get this thing apart very soon.

I did get a new set of tires: 285/75-16 Firestone Destination ATs. They don't look as cool as the 305/70 General Grabber AT2s did, but these have a 840 lb. heavier maximum load, have an 80 psi maximum pressure (verses 50 psi for the Generals), and they are an E load range tire instead of D load range.

 

[carguyz28]

Good tire choice. They will work well. And last longer providing you don't drive to hard haha.

 

[Michipicoten_SuperDuty]

Welp, I've started to get her apart. As discussed in my other thread (here) I also desperately need to install the new oil cooler. As the picture shows, I've just got it apart almost as far as I need to. My next step is to hook shop air to the high pressure oil system and see if I can hear any leaks.

 

[NJ2005X]

Michipicoten--have you resolved this issue. I have the problem that from all the comments, seem to be my IPR screen. (hoping). 2005 -- from cold start, then dies out. The oil was really really old. changed it, and it just did the same dieing deal again yesterday. Can you replace just the screen, or is integrated in the IPR. do you know if Advance auto rents that special tool? i have read where people have made their own too, but I can not weld. can you use a crow foot?

 

[Michipicoten_SuperDuty]

Michipicoten--have you resolved this issue. I have the problem that from all the comments, seem to be my IPR screen. (hoping). 2005 -- from cold start, then dies out. The oil was really really old. changed it, and it just did the same dieing deal again yesterday. Can you replace just the screen, or is integrated in the IPR. do you know if Advance auto rents that special tool? i have read where people have made their own too, but I can not weld. can you use a crow foot?

I have successfully replaced the IPR. As you can see from the pictures, the one I pulled out was missing the screen. I didn't try just replacing the screen, I just stuck in a new IPR.

Anyway, a new IPR did somewhat help my serious lack of power before operating temperature, but it did not help my cold start issues. Everything is pointing towards a HPOP leak at this point.

Because you have the new style HPOP I understand they are less likely to fail, but if you do in fact have a high pressure oil problem, there are a number of other places it could be happening (stand pipes, etc. etc.). You could attempt to diagnose it by pressurizing the high pressure oil system with shop air (~100 psi). Again, all this is assuming you do in fact have a high pressure oil problem. It seems to be a very common problem with 6.0s, but there can be other causes.

My other thread concentrating on the high pressure system is here: Removed Oil Cooler - Very Low Oil In Sump! Cause Of HPO Problem? - PowerStrokeNation : Ford Powerstroke Diesel Forum

Back to the IPR, you can get a replacement screen here: IPR Seal Kit 6.0L Powerstroke

As far as the tool, I'm decently familiar with Autozone's rental tools, and I'm almost completely certain they don't offer that socket. I was very happy with the one I bought - this one: Lisle 68210 IPR Socket for Ford Diesel 6 0L | eBay

I have read of other people using other tools for removing the IPR, but I can't imagine it's easy. The socket makes it a lot easier, and for $30 I think it's well worth it.

Sorry for the long-winded reply, but good luck! And, Merry Christmas!

 

[NJ2005X]

Thanks for the comments. It sounds like IPR's seldom go bad, just the clogging, or ripped screen and o rings. I used your link for the seal kit and it lists out of stock. So many other online locations to buy it - any idea of trustworthy sites? Amazing, the mark up of some sites. 25.00 average - but Bulletproof had it for over $50.00!! at that price, just buy a new IPR.

 

[Michipicoten_SuperDuty]

I'd give Accurate a call and see what the lead time is. I have talked to them before, and they have been helpful.

I'm not sure of how frequently the IPR is actually bad, but I have read that crap passing through them is a big cause of problems. This goes along with the screens going missing. In the worst case, a new IPR can be had for ~$160.

 

[Michipicoten_SuperDuty]

Here is note and a picture to anyone who finds a situation like I found: Pull out an IPR and not find any trace of the screen on the end.

When I originally replaced the IPR I did it with only removing the necessary, so I couldn't look down the port. Since then I have driven the truck ~1000 miles with a new IPR. I'm now in the process of replacing the HPOP and oil cooler, so I have the HPOP cover off. Thankfully, I had the IPR removed again, and with the HPOP cover removed, thought to peer down the IPR port.

As you can see, the "missing" filter was actually stuck at the end of the IPR port. I'm not sure of what effect this may have – if any – but it isn't right.

Just a word to the wise. You live and learn!