Hi guys. Apologies for the long post, but I'm hoping someone can help me out with some problems I'm having with the truck. I have an 03 6.0 with about 89k miles that started acting up yesterday.

The truck started fine cold in the morning, but once warmed up (20 minutes or so driving), it didn't want to start. Finally, after letting it crank for about 10 seconds, it caught and started. I took the truck home, tried to start again in my driveway and same thing - took 10 seconds of cranking to get it running. I went in, got my tablet with torque app and pulled the following codes:

• P0401: Exhaust Gas Recirculation Flow Insufficient Detected
• P132B: Unknown code - More information may be available on the web
• P2290: Injector Control Pressure Too Low

I cleared the codes, let the truck cool off over night and started fine this morning, then drove hard for 20 minutes and exact same thing happened (shut it off and it didn't want to start again). I scanned again and this time - I got these codes:

• P1000: [Ford] OBD-II Monitor Testing Incomplete
• P2290: Injector Control Pressure Too Low

After the truck warmed up this morning, I was watching my HPOP pressures and saw about 6-700 psi at idle, 1000ish at constant 30mph speed, and up to 1800 or so when accelerating hard.

I searched a bit and couldn't find "normal ranges" for HPOP, so I'm wondering if these are normal, if there's something else that could be triggering the problem, or if I'm cooked and am going to be out $2k for an HPOP replacement?

 

I would have a look at your ICP sensor and see if there is oil in the electrical connection. Do you have any gauges that read live data like scan gauge II or one of the smartphone apps like dashboss for IOS devices or torque pro for android? We will need to know what the ICPV's are at KOEO. You should also pull and clean the EGR valve with carb cleaner, just be sure you do not get any carb cleaner in the top side of the valve ( where the electronics are )

 

I have Torque Pro. I didn't have ICP loaded , so found the formula below. Assuming that was the right formula for ICP Voltage, I am getting about .2volts (actually .175-.180) with Key on Engine off.


ICP Voltage
PID: 2216ad
Unit: VOLTS
Max/Min: 5.0/0.0
Equation: ( ( ( A * 256 ) + B ) * ( 72 / 10000 ) ) / 100

 

While that is a little bit low, it should be like .20 to .25, I would still pull the electrical connection off the ICP sensor and look for the presence of oil, if you find oil you need to replace the ICP sensor and pigtail. If that is not the problem its likely a HPO leak and you will need to do the air test to find the source.

 

P2290 is set when ICP desired is below ICP actual for "X" number of seconds with the engine running. It can be an ICP sensor, IPR valve, HPOP or HPO leak.

I used to get it while running certain tunes, but mine ended up being a trashed IPR screen.

 

Thanks for the input. It sounds like this may be a little over my head on this one. I'm thinking the best thing might be to bring it to an expert.

Does anyone have feedback on a good diesel mechanic that can actually troubleshoot this without just throwing parts at it - in Eastern Massachusetts? Unfortunately for me, there's a ford dealership right down the street, but I really don't them trust after my last experience.

 

IIRC right before my HPOP went out on my early 04 I was getting about the same numbers. Can always pull the IPR valve and check it out make sure screen isn't pushed in and intact. Make sure that there is no oil in ICP wire harness. Something you can do your self pretty easy. The P0132B I had once before and think it had to do with the turbo but I would do some research before taking my word.

 

Where in mass are you there's a few great shops around

 

I am in Concord - which is about 40 minutes north-west of Boston. I hear Mass Diesel in Bellingham is good, but they're about an hour from me. Not terrible, but if there was a place a little closer, it'd be a lot easier to arrange rides for drop off and pick up.

 

I thought I had read that the IPR valve was a nightmare to get to on the 03?

 

Mass diesel is a great choice, not sure how far it is from you but there is Affinity Auto in New Hampshire. Joe wermers owns it I believe and really knows his stuff. Probably a little better pricing as well

 

Thanks - turns out Mass Diesel is only 45 minutes from my house - so I just called and made an appointment with them. I spoke with the mechanic there and he seemed to think it was the IPR sensor. Hopefully that's all it is - I'll post again once I get the truck back.

 

Well let me clearify a little the wire harness easy IPR is another story. You can buy the IPR socket off of Amazon for about $20. I have one and keep it in the driver side door for use on my oil filter. Hope they get you fixed up and out the door without dealing out to much cash.

 

I got the truck back from Scott at Massdiesel performance about a week ago. Turns out it needed an HPOP and ICP sensor. It also needed an intake gasket kit and silicone hose and o-ring (for the intake and turbo). I also had him put in a coolant filter while he was in there. The problem seems to be fixed now. The truck starts up even easier than before when cold (pretty much instantly) and within about 1-2 seconds of cranking when it's warm.

Not an inexpensive trip to the shop, but I think Scott was very reasonable - especially given my previous experiences with the local dealership.

Sorry I can't report that was some quick and simple fix that worked for me, but hopefully this helps someone with similar problems in the future.