Intermittent Starting Problem? - Diesel Forum - TheDieselStop.com
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99 & up 7.3L Power Stroke Engine and Drivetrain Discussion of the 99 & up 7.3L Power Stroke diesel engine and drivetrain in the 1999-Up Super Duty trucks and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 7.3L Power Stroke engine.

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Old 08-13-2013, 04:14 PM   #1 (permalink)
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Intermittent Starting Problem?

I have had an intermittent starting problem going on for 2 months now. Truck will start and run fine, then park and shut off and it won’t start. Truck cranks hard and fast but doesn’t fire. Then after 10 minutes or so, will start right up and run and start fine for a week or so then same scenario. Has done this a dozen times.
Well… now it won’t start at all. Cranks hard and fast but won't fire. Tried 10 times over past 4 days.
Hooked up AE and have 2 codes…
“P0603 Internal control module keep alive memory error”
“P1212 Internal control pressure lower than desired (engine crank or run)”
Cleared codes and it started right up… *** ?
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Old 08-13-2013, 04:46 PM   #2 (permalink)
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Try to catch it when it won't start and hook AE up to it. Monitor ICP sensor data (in PSI), IPR duty cycle, cranking speed, voltage, Injector PW, engine oil temp, and anything else you can think of. I suspect your ICP sensor is giving false data - you might try cranking it with it unplugged one of these no start episodes to see if that helps.
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Old 08-13-2013, 08:58 PM   #3 (permalink)
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Where is the ICP sensor? Can I drive with it disconnected? I read that if it has oil on it it's bad... true? How much for a new one?
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Old 08-13-2013, 09:04 PM   #4 (permalink)
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Front inner aspect of the drivers side head. You can drive temporarily with it unplugged. Oil penetration is indicative of a bad sensor. They run about $100


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Old 08-18-2013, 12:41 PM   #5 (permalink)
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Thought it was fixed... now on side of road, died while running, got it started after 15 min of screwing around, died 10 min later and won't start. Same codes...
In control module stuff.
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Old 08-18-2013, 01:48 PM   #6 (permalink)
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If it will restart after it cools down, your IPR solenoid could be toast. It will get heat sensitive as it starts to fail - working when cold and dying when hot - then miraculously working again after it cools down. That could set the ICP code given it won't be able to generate the pressure it wants.
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Old 08-18-2013, 02:46 PM   #7 (permalink)
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Okay... so mother-in-law comes and rescues family from side of turnpike and pal comes to tow. He asks "did you unplug stuff?" to which I reply yes... he proceeds to unplug same stuff, no start. He unplugs EBV sensor and it starts right up, start going home, 2 miles later dead, won't start again. I throw things...

Where is IPR solenoid? Can it be tested?
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Old 08-18-2013, 02:55 PM   #8 (permalink)
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The IPR solenoid slides over the IPR valve. It is located at the rear of the HPOP on the driver's side. Basically, if you lean over the HPOP reservoir and look down, its in the recess kind of between the fuel filter and where you unplugged the ICP sensor. No real way to test it, but you have AE so you could do some measurements that would narrow it down. When it won't start, hood up AE and monitor ICP sensor data in PSI and IPR duty cycle. If the IPR duty cycle is hitting around 65% and you aren't building IC pressure to above 500, then the solenoid is probably bad.
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Old 08-18-2013, 03:13 PM   #9 (permalink)
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When trying to start I'm reading 40-44% and 147 +/- psi... does that sound right?
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Old 08-18-2013, 03:29 PM   #10 (permalink)
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Okay... it started again. Now running I'm reading 1150 psi and 19.5% at 2000 rpm. Both were less at idle.

Just heard truck die outside... CRAP! At least it's in the driveway.
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Old 08-18-2013, 03:33 PM   #11 (permalink)
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Just checked again... gets to about 65%, 150psi when cranking and not starting.
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Old 08-18-2013, 03:37 PM   #12 (permalink)
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So it's not hitting your desired 500psi... sounds like IPR solenoid is bad, yes? I've seen IPR clean video but no solenoid fix video. do I need new part? How do I know whether to rebuild or replace?
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Old 08-18-2013, 03:54 PM   #13 (permalink)
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Your symptoms fit perfectly with an intermittent solenoid issue. Very, very common problem.

Unfortunately, you can't buy the solenoid separately - you're going to need to buy a new IPR. Whether you choose to put the new solenoid on your old valve (which could be done in less than a minute) or pull your old valve and replace the whole thing is up to your. Probably would be fine just to put the new solenoid on until you get a chance to swap the whole valve.

Changing the solenoid is a breeze - pull the wire harness loose, remove the tin nut, then spacer and slide the solenoid off. Replacement is the opposite.
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Old 08-18-2013, 05:48 PM   #14 (permalink)
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Just got back and read yer reply. I was taking out and rebuilding my IPR. put it all back and same readings... about 150psi at 65%, wont start. Read somewhere to measure ohms across solenoid prongs, got 11.5 then 10.4 when it cooled completely. Guess I'll go get a new one. Thanks for your help. I'll post when it's done on Tuesday... gotta werk tomorrow.
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Old 08-18-2013, 05:52 PM   #15 (permalink)
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Yeah- your problem wouldn't be fixed by rebuilding the valve- you need another solenoid.


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