Ok.. Here's the issue(s) I'm currently having. The truck is a late build 2004 F-250 6.0l with 131k miles. No problems starting cold or hot. New oil cooler with egr delete after i noticed my delta was 40 degrees... All filter are Motorcraft replaced less than 1000 miles ago. Now onto the problems I'm here for:

Problem #1 After the engine warms to normal op temp, occasionally the engine will fuel up like I pushed the pedal another inch. It does this at any speed even 0. That's right, even at red lights when little old ladies in their Prius are in front of me. It scares the crap out of me an them. 4 to 5 seconds later the chaos is over.

Problem #2. The truck will sometimes stumble like its in limp mode or even die like I turned the key off at red lights. It fires right up after 1 or 2 seconds of cranking. This problem can sometimes coincide with 1 if I let off of the pedal immediately after the rev up. It will limp, with very little if any smoke at all.

The icp sensor is new, haven't noticed any chaffing on any harnesses. Ficm replaced 2 years ago. My question is; I know this isn't a symptom I see anywhere but the fact that is fueling up with no smoke and dying with no smoke, limping with little to no smoke, I don't see this as an injector or or ficm issue. It also happens when engine is at op temp. So is the ipr acting erratic??? I don't have the means of checking duty cycles right now and I don't mind replacing an 8 year old part. Has anyone had this same issue?

 

What you describe points at the icp sensor or the icp connector/harness

 

I'll check into it again. I purchased an ICP sensor on eBay for about $75 but I didn't replace the harness since there was no evidence of damage or oil contamination. It seemed like it might have helped for a few days but as the days got warmer the problems got worse.

 

Im thinking your symtoms are IPR Valve relaited IMO

Pull IPR and check the Screen its probably full of junk ESPECIALY since you just did the Oil Cooler


Do you have anyway to monitor ICP and IPR%????????????

Plus pretty slim chance the New ICP you just installed is Bad and if it was the IPR is probably the root cause

 

Here is an example of the kind of things you can experience w/ that ICP and its location:

A Cautionary Tale (IPR Plug) - Ford Powerstroke Diesel Forum

From the link above:

"Well... one thing led to another and I ended up taking off all of the heat-shielding and wrapping from both the IPR and ICP leads. And boy am I glad I did because I found something VERY interesting. Sure enough, the wires going to the ICP sensor were melted together and shorting out, but not down by the plug, but rather up by the joint where the IPR branches out. That's maybe 6-7" away."

 

I had the equipment to do so back when I was the manager of an Advance auto but now I don't. The problem was there before the oil cooler but nowhere near as bad. The screen under the cooler was ripped almost beyond recognition. The way I saw it was if the oil temp was bad it was doing nothing but damaging sensors, injectors, and everything else for that matter so I replaced the ICP at the same time thinking that was it. I just knew it wouldn't be that simple.

 

I'll check the IPR harness before I order one. When I removed the cooler I did notice the foil shielding was in bad shape. I did my best to repair it but never looked at the wires. I'm going to kick myself if the harness is shot...

 

I bought a ICP sensor off ebay once,it lasted about three months.In the last 5 years my 350has eaten 4 sensors and one pigtail.IIRC.

 

Great Idea to check that Harness its Literealy in the OVEN Back there

Great Call on the Harness Guys

That ripped screen on the HPO reservoir was also letting junk threw to the IPR

 

Wonder why its eating so many ICP sensors

Is it Blowing Oil threw them????

 

I think it may be time I invest in a scan gauge before I throw anymore parts at it. The pigtail I can check easily on the ICP and the IPR, well, that's a little harder to get to. Lol. I think I'll check out the duty cycle when it's acting up an go from there.

 

Two blew oil two cooked.I was running some hot tunes for a while (15-1600*)and assume that the up pipes cooked them.The last one is about a year and a half ago.

 

The way my luck runs I wouldn't be surprised I ordered a bad ICP. So when I get the scan gauge, what numbers should I expect at idle/wot. Also what should I look for when the truck acts up? Voltage and percentage numbers jumping? The only problem I foresee is when the truck acts up at idle then surges/limps up and down, so does the rpm. Wouldn't that change HPO pressure therefore changing ICP voltage and again in turn causing the IPR to to do the same. It seems like the only way I could really properly diagnose this is when the truck wants to take off on its own.

 

Might be worth a trip to the dealer or a data log drive with a puter.

 

That's not a bad idea. Atleast I have a game plan now and it first involves pigtails. I appreciate the help guys. I'm sure I'll be using this site often.