I've just ran into an issue that has me asking this question. First off, some information on what happened, was ripping down the highway on my home, came to a stop and the truck stalled. After pulling the codes, it came up with ICP Low pressure during a specified time. 2290 i think.. then after cranking and no starting came up with a 2291 ICP pressure low during crank. Ok, after sitting for about an hour at -28 Celsius it finally started again, drove it home, as soon as the engine idles down below 1000RPM it dies, same 2 codes pop back up. wait an hour, it starts. Anyways, took it into the shop, installed a new ICP sensor. let the truck idle in high for about 45 minutes, no stall! shut it off to plug in Modis, now no restart. and only code 2291.

Now the question... Any ideas??

Truck info is 2003 6.0L 220,000km. Replaced FICM at 190,000km (just cause it was weak) running 5w30, anti-gel additive (from FORD), change the oil every 5000 Religiously! MAP sensor done 25,000km ago along with MAF sensor.

Only codes that show up are 2291 and wont start until cold.

 

I am thinking that either your high or low pressure oil pump is out. Do some searches on that. Others will be here to give a better answer.

 

My bet would be a High Pressure Oil leak or perhaps HPOP issue.

 

May just have a hpop leak. When oil is warm it is thinner and can leak more easily.

 

Where would I begin to look for a High Pressure oil leak?

 

How willing are you to remove the FICM, turbo, intake manifold, and the EGR cooler to get to the HPOP cover and HPOP itself for troubleshooting? Otherwise:

One way to diagnose for an HPOP leak without a teardown: Remove the ICP sensor --- use this hole to pressurize the HPO system with air (it would be helpful to have the turbo off, so the FICM and intake tubes also need to also be removed). I believe you would then need to have a way to send 12V power to the IPR, but only for 30 seconds or it will burn out.

Remove the oil fill cap, remove the CCV hose that goes into the air intake from the other valve cover, take a piece of heater hose and listen in BOTH spots after commanding the IPR valve to close (again - only for 30 seconds). If you hear air coming from either one it's probably a leak in one of the oil rails. If you hear air coming from BOTH sides it's probably the HPOP or branch tube ..... IIRC.

Note - I have not done this procedure, so if a Tech or other FTE member would care to correct any mistake I have made, I would appreciate it.

Also -

If IPR is at 80% while at hot idle, then you have high pressure oil leak, failed pump or a bad ipr valve.
IPR should be around 22-24% at hot idle; up to maybe 30% but that maybe a little too high.

Lastly:

There is a hole that is situated just above the HPOP drive gear. If air is heard/felt exiting this hole when air testing, this is normal if IPR duty cycle is not commanded to 100% because that is the exhaust passage. The way to condemn a high pressure oil pump is to air test it with the turbo oil supply tube removed from the top of the oil cooler base. If air is heard/felt from this port during air testing, the high pressure oil pump is bad.

 

I might be off base but 03's were notorious for icp and icp pigtail failures. Cheapest and easiest place to start. Heat could be affecting them. If it was an 05 I would be looking at the hpop/stc areas.

 

check the ipr for a damaged screen. run an injector buzz test. odds high side pump issue on 03/04 engine.

 

Could you comment on post #6 - is it useful/accurate or way off base?

 

He had mentioned that he got a new ICP, so I didn't think to suggest anything w/ it. I assumed he would at least inspect the pigtail - but maybe not. Hopefully it was not oil soaked!

 

mark your info is good. even better for an engine with the icp on the valve cover. the issue comes in to play if its an early build they are diaged much more like a 7.3.

 

as always - thank you - this all gets put in my spreadsheet.

 

ICP Sensor was changed, pig tail inspected, it was clean. some buildup under the heat shield but the plug was clean, i used sensor clean on the plug just in case, spotless and reconnected. it is an early-build 6.0L so yeah, the ICP is what i like to call a little ignorant to get at!

 

Im hearing alot about this STC fitting, question is does the late 03 early 04 have this fitting. I have removed the turbo, intake, ficm, etc... I have the ICP adapter and I presurized it to 110lb. I can hear air coming from under the HPOP cover. I havn't gotten the Intake or EGR removed to be able to remove the Cover plate.. But I am wondering if this is going to be the rear branch tubes or if there is a fitting between the two on this model.

My biggest concern is, am i removing the tranny, flywheel and rear engine cover?

 

03/04 no stc fitting.
odds are pump shaft seal. if you remove the oil filter can you hear air comming from the filter housing? if not try bumping the engine over just a little bit and see if that changes things.
for what its worth I have not done / seen / heard about a failed branch tube on 03/04.