There are also deep sockets available on eBay for about $26 shipped.
LISLE 68210 IPR SOCKET FOR FORD 6.0L DIESEL | eBay

 

So, I pulled my IPR and replaced it with a known good IPR. Also replaced my ICP pigtail. IPR looked good, very little metal and screen was in good shape.

Still no start. When cranking it smells like poorly burnt diesel, and puts out a little black smoke.

So, I am still not getting any codes from my scangauge II and my SCT. NONE!!! The truck will not start! AHH!

So I am guessing HPOP? I still don't have normal symptoms of HPOP failure. WTF?

Any ideas before I replace the HPOP?

 

How far have you got down the check list in the Tech Folder?
https://www.ford-trucks.com/forums/9...condition.html

 

1. What oil and fuel filters do you use? How often are the filters changed?
Motorcraft Filters only, Changed every 10-15,000 depends on condition.

2. Could you have gotten bad fuel?
Yes, I could have. But I didn't I checked it and it looks/smells good

3. Is your fuel aerated (ie air in the system)?
I pulled the cap and checked to see if there was compression gas coming back. No bubbles. All caps and o-rings are good.

4. What oil do you use and when did you last change it?
Rotella t6 changed >3000miles ago

5. What is your oil level?
Middle of the stick when cold and on flat ground.

6. Any hoses or electrical connectors loose/unattached under the hood?
Checked them all. No chaffing, no disconnections.

7. Any exhaust or intake leaks (at boots or pipes)?
None

8. Check your air filter "filter minder".
New air filter within last 15,000 miles and rarely operated in dusty conditionsd

9. Have you pulled your EGR valve or ever changed it out?
Pulled and threw it in the garbage can

10. Are you getting good fuel flow?
New HFCM, good presssure (70psi)

11. Bad ICP sensors and/or harnesses can cause power issues, but they usually have other symptoms like rough running, bucking/surging, and even no-starts.
New ICP sensor, repaired wiring harness

12. Wire chaffing can be an issue with these trucks.
Checked all normal places

13. You could have a clogged catalytic converter - but it is fairly rare.
Its hard to clog something that isn't there

14. You could have a bad FICM, usually there are quite a few codes w/ a bad Fuel Injection Control Module.
No codes, FICM was switched out with a known good working unit. No change

15. You could have clogged fuel lines or a weak fuel pressure regulator spring.
70psi

16. Injector stiction.
Never had an issue here before, and it I would think that it would be a gradual issue and not instantaneous.

17. The turbo could be sticking:
VGT is in working order, cleaned and tested a few thousand miles ago.

18. Could have a bad EGR valve:
Already been discussed


19. Other things that are more complicated to troubleshoot and more expensive to fix (those not already discussed):
i. Sensors - Bad EBP, MAP, Baro, MAF
ii. Actuators - Turbo VGT
iii. Other instrumentation issues - IPR valve
iv. Mechanical - Bad fuel pump (HFCM), bad injectors, or a bad HPOP (high pressure oil pump). Usually a "no-start" condition will be experienced with a bad HPOP. It is a fairly big/expensive job to replace this pump.
v. Sometimes the most recent flash applied by the dealership can improve performance. They usually contain some desirable upgrades.

 

do a ballon test on each bank. also a possible reason to not start.
unplug each injector one at a time and see what happens.

 

Guess I blew it on the IPR
But I still think its a HPO problem

maybe an Injector top oring is blown out
or the oil side of an Injector is stuck on

Have you tried an air test on the HPO system
or cranked with the valve covers off to see if an injector top oring blew out and is a Gushen oil out

At 675 ICP I dont think the HPOP blew the BB out if the BB blew out you would have 0 HPO maybe 70 psi tops but not likely
Check everything out before changing the pump

I would do an air test of the HPO system next see what happens there

 

Blade what is a BB?

 

On the 03/04 HPOP's there is a ball bearing that's peened into a machine port as a plug that can blow out and cause a pump "failure". The easy repair for this is to tap the hole and put in a pipe plug.

 

heres a good thread on it Duke

HPO BB 03-04 pump
No Base oil Pressure - Page 4 - Ford Powerstroke Diesel Forum

whoever designed this shure had a DUMB Moment

 

Well, after mass amounts of testing, questioning, and diagnosing, I finally narrowed it down to the HPOP. Replaced it last night and the truck runs better than it has ever run.

Thanks everyone for your help. I owe every one of you a beer or two. Cheers

I think this pump was gradually wearing out. Is that how these pumps normally fail?

 

Usually they just quit running but who really knows? Up until the last couple of years there really hasn't been a lot of ICP/IPR/HPOP monitoring that I know of; kind of like the ECT/EOT delta thing. I suspect as time goes on and folks watch ICP more we'll begin to see pump wear issues vs. HPO leaks and catastrophic failures.

Glad you got your problem solved and are back running.

 

post 14.

 

That's why you get paid the big bucks

 

Yep Cheezit you were right! Thanks

 

Right On Cheezit

Must of been the Pressure/No Volume things you were Talking about

What Exactly are you Looking for When you run those tests and Deadhead the HPO pump an ICP of 4000psi or what