Friend has a 02 F450 7.3 that runs rough and stalls only when warm. It has almost 700K km's on it and he has previously replaced the glow plugs, both cam and crank sensors, IPC and IPR. He has also ordered a set of injectors and harnesses which will be installed later this week. I have scanned for codes with my NGS three times so far. First time he had P1316, P0344, P0476. Replaced cam sensor and cleared codes. 2nd time he had P0476, P1280, P0232 and P1211. He replaced ICP. 3rd time he had P1280, P1316, P1212, P1210, P1211. It starts and runs fine when cold. I monitored the PIDs when cold, ICP is stuck at default 725psi, IPR 14%, MAP 14.5%, RPM 700. No change when ICP unplugged. When it's warm and running rough readings are all over the place, IPC 1400-2700psi 1.5-4V 2.9-3.9ms, IPR 4-15%, MAP 14.5%. There is no response from the throttle. IPC returns to 725psi when unplugged. Blue/white smoke. At one point IPC dropped to 425psi and it ran fine but then it went nuts again. KOEO IPC reads 2700psi but drops to zero almost instantly. Cleared codes and ran KOEO and got P340,P1210. Two injectors sound dull during the electrical test. I also think the EBPR is stuck cause I've never seen it move during KOER. I'm hoping it's just bad injector seals and the new injectors will take care of it so I really didn't go any farther. Any ideas?

 

Sounds like your ICP is bad or the wires going to it are loose or there is a short. ICP should be about 800-1000 at cold idle and about 475 at warm idle. Something else is going on as well, because the truck should start and run with a bad ICP.

 

What scan tool are you using, and is it connected through a Bluetooth device?

After the repairs - did you drive it to get all the air out of the oil, or are you just doing stuff to the truck and idling/revving?

What is your oil level?

What is your fuel pressure?

Assuming the engine is together - do a KOEO test, then disconnect your scan tool. Crank the truck up and go for a drive (about a 75-km drive) to work the air out of the system.

Assuming the truck's guts are splayed out in the garage... do your injectors, warm it up, do a hot-torque on the injectors, button it up, then follow the "truck together" procedure spelled out above.

 

He has changed the ICP twice with no change.
I'm using a Ford NGS scanner. No repairs have been done other than changing sensors. Oil level is good, haven't checked fuel pressure.