[jtavares]

Hello,


I have a early 2004 F350 Powerstroke 6.0. Went to get an emissions test 2 months ago and the truck stalled and would not start again. IPR screen was blown out. Replaced the IPR. Bought hose that can connect to compressor and IPR connection. Had leak in stand pipe. Replaced stand pipe and dummy plug (and all O-rings on injectors - been told since I should have left those alone - lesson learned). Still wouldn't start. Replaced ICP. Nothing. Brought it to a shop. They said the HPOP was bad. Bought a refurbished pump and installed it. Truck started, ran for a short period (maybe an hour total), died and then wouldn't start. Tried other IPRs, bought another refurbished HPOP. Truck started, idled, pressed on the gas a bit, it stalled, and wouldn't start again. Bought tool that connects to compressor and ICP connection. No audible leaks. Bought brand new HPOP from dealership. Installed - lots of pressure (2200 psi), started like a charm. Ran for about 7 minutes with idle PSI of about 550 psi. Turned it off, started it again, no problem. Went to bed, woke up this morning. Tried to start it, turned over, sounded like it was going to start then it died. Now it won't start again. FICM reads 47.5. IPR is at 84%. Oil pressure is only at 31 lbs! This is crazy, we REALLY need help. We've been at this for close to 2 months and are desperate to get this truck running today. Any help would be greatly appreciated. Thanks in advance, Jennifer


PS. Low pressure oil is working well.

 

[ByronF350]

Have you tried unplugging the ICP sensor? that could be bad

 

[dillon134]

It is possible that there is a significant amount of small debris in your HPOP system and it keeps plugging up your IPR screen. Have you rechecked it?

 

[jtavares]

Yes, we've tried a new ICP sensor as well as just unplugging it to temporarily fool the system into thinking there is enough pressure to start. Every time it dies, the first thing we check is the IPR screen. Each time it is clean and functioning. Went after work yesterday to get a 4th pump from the Ford dealer (have tried 2 refurbished and this is the second new one). The mechanic gave me a used IPR from the shop and asked us to try it first before replacing the pump as he didn't trust aftermarket parts. It didn't make any difference. Hubby will try the latest pump today. I'm not even a little bit optimistic. This is horrible.

 

[Maryland dieselnick]

Make sure the wires at the ipr connector inside of its heat shield sleeve are not chaffed.

 

[jtavares]

We put brand new wires on the IPR.

 

[teamroper60]

Did you test for leaks in the hpop system after these repairs? Your post says you replaced one standpipe. Did you check the other one? With multiple HPOP changes and 84% on the IPR and only 31psi ICP, it is screaming that there is a leak someplace.

 

[JonGage]

Second what teamroper60 said, you HAVE a leak somewhere. The IPR should never go to 85% when you are starting the engine. ( which is fully closed.) It is trying to build pressure and cant because of a leak.

I bet you pinched an O-ring when you disassembled the standpipe system. Or any of the oil/fuel rail system that was disassembled. They do pick rather easy, especially if the O rings were not lubed when you pushed the rail back onto the injectors.

03/04's HPOP's fail and have to be replaced. That is a given.

Purchase the tool to conduct an air test of the HPOP system. It screws into the IPR port and pressurizes the system with air. You will find the leak if you listen to air rushing out. There is always some air that come out around the HPOP area, that is because of a drain hole for IPR. Basically a hole that it dumps the oil, it runs back into the crankcase.

Also what are you using the confirm these numbers. Auto Engunity??? Scan gauge?

 

[jtavares]

Found the cause of the low pressure - the o-ring on the HPOP had blown out. Got it all fixed up and went to try to start it. It turns over but it's stuck on something, even though we were extremely careful not to let anything fall in anywhere. Will investigate this morning. JonGage, if read my post, I have two tools that conduct air tests, one that connects via the ICP, and one that connects via the IPR. The numbers came from my SCT Livewire.

 

[jtavares]

Ok, after manually turning the motor we found that we had an air lock in the system. With each manual turn of the motor some air was able to escape. Did that for about 10 minutes and the truck started beautifully and ran great. Let it run for about 20 minutes, shut it off, went to start it again - NO START. If history is repeating itself, the d-ring on the top of the HPOP is blown out again. Does anyone know why this would keep happening? Does anyone know if there is a NEW and IMPROVED d-ring for these motors?

 

[ByronF350]

I think that it takes a few HARD drives with the truck to get all the air completely out.

 

[jtavares]

I'm embarrassed to say, we figured out why the d-ring kept blowing. We were using the image attached as a guide as to where to put the d-ring (found online). By following the image, you put both the skinny o-ring, and the d-ring on top of the pump. Bought a new set of rings yesterday and it came with a diagram showing where to put them. We were putting the d-ring in the wrong spot! Jeez! Glad to have figured it out though. Hopefully today will be a better day (once we get it all put back together). Live and learn.