no Start condition:
ICP gets up to 84PSI
IPR Duty cycle stays in 30s (Which makes me think valve is OK?)
RPM over 100
FICM 48V

Basically looks like a HPOP leak.

According to OASIS report truck was treated for a no start at least 2 times in the past.

The last tech comment got cut off in the OASIS report I got:

Tech Comments
VERIFIED CONCERN. NOTHIGN VISUAL. RAN HS NS DIAG SHEET STEPS 1 8 AND FOUND P2291. RAN PIN POINT AQ1 AQ4 AND IN STEP AQ4 WAS LED TO HS NS DIAG IN PC ED STEP 10E AND MONIORED ICP AND WAS ONLY BUILDING 100PSI MAX, SPEC IS 5OOPSI MIN. CNT WITH STEP10F AND AIR TESTED HP SYSTEM AND HEARD NO AIR CHANGE IN LEAK INDICATIND IPR FAILURE, R&R IPR PER STEP 10F AND CNT AND HEARD LEAK FROM UNDER........

The entire report ends with that... Now that I'm having the same problems I REALLY want to know what was done. Don't want to open up the HPOP cover just to find that the SCT fitting update has already been done.

Anyone want to venture a guess as to where he heard a leak under and what was done to resolve it?

Truck ran fine when I parked and went into store, then would not start when I came out.

Do the dummy plugs and stand pipes leak in the 2005 or am I looking at the Sct connector in the HPOP housing?

 

The IPR is the problem

30% IPR is not right

the IPR should jump to 75-90% when trying to start and then drop to 30% or so when running and then when upto normal temp leval out at 20-24% IPR

check the wiring to IPR its in a Hot spot make shure fulley plugged in since it just went threw a Majoir Operation

If that^^^^^ Fails Pull IPR and check the screen for damage replace if needed

 

Post up the part numbers in the parts list section of that report. That will indicate all parts replaced.

As far as where the sentence cuts off, your guess is as good as mine. But something to bear in mind is whenever a warranty repair claim is submitted to FoMoCo after the repair is completed, it is done by the dealership's warranty administrator, NOT the tech that did the repair. In other words, the actual tech comments are literally re-typed on an online claim submission screen by the administrator, who is either only re-typing what was hand-written on the work order hard copy, or reading it off another computer screen (if the dealer is equipped with ERO). This is why comments can contain some mis-spellings or type errors. Remember, the warranty administrator knows NOTHING about vehicles, how they work, the purpose of the tests, diagnosis process done by the servicing tech. Also, the tech comments section of the report has a limited amount of word space. So, if a long drawn out process occured, or there's a LONG story, it will get cut off.

As far as '05 dummy rail and standpipes go, only the later model year '05s (EBP sensor secured to FICM mounting bracket, no MAF sensor) are more prone to failing the lower d-rings like to '06 and '07s. The earlier model year '05s (EBP sensor secured to T-Stat housing, equipped with MAF sensor) weren't prone to this failure.

HOPE THIS HELPS

 

Thank you! I haven't seen that stated before. Might be 1 of the few
perks in having an early '05.

 

Thanks for the insights.
I ordered the IPR wrench so I could take it off. Pressure testing the hpo system with air, it seems like the IPR is functioning(when I actuate the IPR with AE the air leaking sound stops).

I went ahead and ordered the updated dummy plug and standpipe kit from tousley. Is this a bad Idea? Mine have the 1/2" square drive socket. I do have the early '05. I did pull the dummy plugs and they look fine. The standpipes didn't come out with the top part and I don't have the tool to pull them so I have to pull the oil rail to get them out.

Not sure if I should even bother if I don't have any leaking sound?

Would I be able to hear a loud and clear leak in the STC fitting from under the pump cover and turbo? I did order the STC fitting update kit also.

Just re-checked my data. IPR Duty did go up to 84.77% when cranking and in that last attempt I did get up to 197 PSI ICP

 

Here is the full OASIS report that I have. The original has links to the Ford Tech details that require a login. They didn't copy into this form right though
Details
That is what they look like in the report

VIN 1FTWW31P45EA63005
Vehicle Line T/F7 Market Derived Code F
Body Cab T/BC Ver. Series T/CD
Drive Type T/E
PLT CD A1 TRS CD T/BE ENG CD T/YB
Production Date 16-SEP-04 Warranty Start Date 02-OCT-04
Selling Dealer 152096 Selling Country USA
AWS Claim Key Time In Service Labor Hours Dealership DIST (Miles) Repair Date Prefix Base Suffix Doc
Details 9095722 39 1.2 EDDIE YAKLIN FORD LINCOLN MERCURY, LTD. 96859 05-DEC-07 5C3Z 9F452 AA 138193D
Customer Comments CUSTOMER STATES AT TIMES LACKS POWER 8 MPH THEN CLEARS UP NO CHECK ENG LITE
Tech Comments 96867 CC 55 CAUSAL PART 9F452 072109B TEST DROVE VERIFY ENGINE LACKS POWER,RAN DIESEL PREFORMANCE DIAG.VISUAL INSPECTION,PASSED.OIL AND FUEL PASSED.INTAKE AND EXHAUST RESTRICTION,PASSED.RAN KOEO,KOER HAD CODES P0401,P0404,P1335.RAN EGR TEST. FAILED.REMOVED AND REPLACED EGR VALVE PER TSB 07 21 9,CLEANED CARBON FROM INTAKE PORTS.CLEARED CODES AND RETEST HAD CODE P0299.TEST DROVE AND
Details 11772096 79 1.4 EDDIE YAKLIN FORD LINCOLN MERCURY, LTD. 179527 28-MAR-11 5C3Z 9C968 CA 192930H
Customer Comments CRANK NO START AFTER REPAIR ON LINE A
Tech Comments PERFORMED DIESEL NO START DIAG KOEO TEST DTC P2291 MAX ICP AT 48PSI UNDER VALVE COVER AIR PRESSURE TEST COMMANDING IPR NO CHANGE HEARD REMOVED AND REPLACED IPR VERIFIED ICP AT 1400PSI AND ENGINE STARTED CLEARED DTC AND TEST DRIVE TO VERIFY REPAIR
Details 11772095 79 10.4 EDDIE YAKLIN FORD LINCOLN MERCURY, LTD. 179527 28-MAR-11 3C3Z 6A642 CA 192930A
Customer Comments CUSTOMER STATES ENGINE HAS OVERHEATED TWICE, FILLED RESIVOUR UP AND DOES NOTICE A COOLANT LEAK
Tech Comments VERIFIED CONCERN TEST DRIVE MONITERING PIDS FOUND ECT 204 DEG EOT 230 DEG INSPECTION FOUND OIL IN COOLANT PERFORMED TSB 09 18 12 REMOVED AND REPLACED FAILED OIL COOLER USING UPDATED KIT, PERFORMED TSB 08 23 01 USING VC9 TO FLUSH COOLING SYSTEM. WHILE TRUCK WAS RUNNING PERFORMING FLUSH ENGINE DIED SEE LINE H
Details 11840134 81 2.8 EDDIE YAKLIN FORD LINCOLN MERCURY, LTD. 181850 04-MAY-11 5C3Z 9C968 CA 194548A
Customer Comments CUSTOMER STATES ENGINE DIED WHILE DRIVING AND NOW CRANKS NO START
Tech Comments VERIFIED CONCERN. NOTHIGN VISUAL. RAN HS NS DIAG SHEET STEPS 1 8 AND FOUND P2291. RAN PIN POINT AQ1 AQ4 AND IN STEP AQ4 WAS LED TO HS NS DIAG IN PC ED STEP 10E AND MONIORED ICP AND WAS ONLY BUILDING 100PSI MAX, SPEC IS 5OOPSI MIN. CNT WITH STEP10F AND AIR TESTED HP SYSTEM AND HEARD NO AIR CHANGE IN LEAK INDICATIND IPR FAILURE, R&R IPR PER STEP 10F AND CNT AND HEARD LEAK FROM UNDER
__________________

 

If your 100% positive the air sound stopped when you actuated the IPR.Than I would not suspect the IPR as the problem.As the IPR is actually a controlled leak.Meaning the higher the % number the smaller the leak or hole if you will.So if your getting 197psi at 84% with no audibale air noise during leak check.I would suspect a bad H/P pump.Without actually being there and assuming your tests where done correctly that would be the road I might take.
Pin point test test Q has you disconnect icp sensor to see if engine starts. Mainly to see if ICP sensor is biasised or not functioning correctly.Basicaly if it sends the wrong info the IPR might not respond correctly to start engine.Again not being there makes it harder to determine the correct cause.

 

Yeah, unplugging the ICP was one of the first things I tried when it failed to start. It would have been soo much easier to fix and ICP than what is looking like an HPOP.

I guess since I have the STC fitting on the way and it's leaning toward the HPOP anyways, I will go ahead and put the HPOP cover and see if the fitting has been updated and if I can hear a leak under there once the cover is off.

 

the 05 HPOP was Good one

Normaly hear a Air Girgle in the Oil Filter hoseing if the pump is bad so check that

I thinking you might as well install the parts you have coming

 

Blade
Yup it is a better pump.But I have found a few that have gone bad.
Joe

 

Right with You Joe

Why I mentioned the air in oil filter hous

 

So I need to open oil filter housing and listen while cranking, or when pressure testing the system?

 

When its under air pressure with the oil filter cap off

 

Update:
-no gurgling in oil filter housing
-IPR had broken screen but still seems to work. when 12v applied the air is stopped.
-No apparent leaks under HPOP cover

 

OK.... so using UL37's method of finding an HPO leak:
"remove FICM relay,Disconnect plug on fuel pump(for saftey),with both valve covers removed as well as pump cover(which you planned on doing anyway),Have some one crank engine while energizing(hot wired to battery,but dont leave it powered to long,you can burn it out) IPR and look for oil pouring out of leaking area.Also you have to direct the turbo oil feed line towards the H/P pump opening so you dont make a mess. Put it simple 100psi shop air verses 3000psi oil pressure with a good pump.If your pump is good and you have a leak it will deffinatly be found."

No leak was apparent... So I hooked up my 5000psi oil filled gauge to the icp port with full 12v applied. Within 5 seconds the pressure shoots up and would peg the gauge if I didn't stop the starter.

so I guess now I have HPO? I'm soo confused.

i'm tempted to put everything back together enough to try to start it.
Can the engine start and run without the turbo installed?