Back in April I had my first taste of random stalling/no hot start issues. After replacing the IPR valve I was back up and running perfect until this week. This was the thread I started about my IPR failure experience.

Truck is a 04 SRW CC 6.0L build date 11/03 170k miles. ICP on valve cover.

Earlier this week I was leaving work (everything was fine on my way into work 10 hours earlier) and my truck did a little surging. It surged twice at parking lot speeds/low rpm. I have never had a surge before. After that everything was fine and evened out. Next day on my way in I felt it surging on my way in to work while cruising around 55/60 somewhere around 1500rpms. I didn't have much time to play with it once I arrived at work but I at least verified that my ICP voltage was steady .24 KOEO and around .9 low idle warm. MAP, BARO, EBP were all normal KOEO within .5. FICM voltages were fine. ICP/IPR reading were normal for hot idle.

When I left work last night everything was fine, I had power and I had no surging. About 5 miles down the road I tried laying into the throttle a a little bit. The engine was trying to work but the boost maxed out at like 12psi. I left off and tried a couple more times with the same results....except every time I tried this I had less and less power. As I coasted into town the engine slowly worked its way down to stalling.I Managed to make it into a parking lot and try a hot restart. Of course it would not restart. My IPR reading showed it was only building 390-410 psi while cranking. I tried unplugging the ICP real quick and still no hot start. After that I called it quits and left it overnight.

Today on my way in to work I stopped by to see if I could start and move the truck into a better spot by a lightpost. It took an extra second or two longer to start and it wasn't a normal peppy start it was a sluggish start. Idled fine and SGII readings were all normal. It has been in the 90's-100's here lately and the EOT/ECT were still up around 90. When I would give the truck throttle it had little to no response. I idled into a parking spot and tried the throttle again...barely any response. Maybe a little black smoke at full throttle. I let it idle for a minute while I scrambled through the SGII looking at readings. The truck slowly lowered RPMs from 700 down to about 400. The IPR was hanging right around 500psi at this time. About as soon as the IPR reading dipped to 490 the truck shut off. Just for fun I tried restarting. No dice.

Since my last IPR failure in April I have serviced the engine oil/filter and both primary and secondary fuel filters. I use only motorcraft filters and the caps are OEM. I did the blue spring at least a year ago. I know I should probably follow the no hot start procedure, but I am probably going to jump right in and check the screen on the IPR valve I just put in. The bad IPR that came off the truck had no metal shavings or plastic...just sand/grainules and some fibers. I will probably be bringing the truck over to my diesel tech person as he has the proper scan tools to dig into the diagnostics. I bought this truck with about 120k and it now has about 170k.

I am 99% sure it had a good amount of engine work done prior to me owning it. I would imagine HG's were replaced or the oil cooler or both. I really do not know for certain. I see that the head bolts have mechanics pen marks on them, shiny HG's, new bolts on y-pipe connections and the cab mount bolts are coated with antiseize. Of course I didn't know to look for this when I got into the truck a couple years ago. I am pretty sure the last owner had the work done and then dumped it while it was still running well. At this point I am feeling like doing the same thing. Very frustrating after learning how to propery maintanance this truck and do all the things that should make it run like a top. Starting to feel like I have one of those cursed engines.

 

Didn't see any mention of your IPR% at hot idle. Should be in the 22 - 24% range if I remember right. Sounds like an HPO leak, but certainly the IPR may be the culprit - it may be full of trash. You'll definitely want to look at the IPR % and see what it's running at hot idle. I recently had a HPO leak and it was at 28 - 29% at hot idle which was too high and truck would not crank when hot. The cold starts sound identical to what you mention above. Not a sudden kick on the initial fire, but with the leak it eased into it...

 

I would have recorded all of my values, but the way things went down this time and how quick it all happened I was not prepared. Just before this all happened the IPR% was around 23-24% low idle. Every xgauge I monitored was in spec prior to this incident. Just like the last time I had a stall issue everything was starting/running as it should. If I get it running long enough to make it hot I will try and check for that.

 

Little update....IPR is fine. Air pressure tested engine and found no leaks. Will be digging into HPOP soon. Being that my build date is 11/2003 I will be getting HPOP part number 4C3Z-9A543-AARM.

Other than the pump itself I will be replacing the screen with 3C3Z-6C683-AB(obviously)...or possibly IPResearch Extreme Duty stainless screen and of course turbo bolts/orings 3C3Z-9T514-AG.

I would like to also replace the HPOP cover gasket, but I am not having very good luck finding the part number. Anyone help me there? I don't think it comes with the HPOP from what I have read. I am assuming that the HPOP comes with everything needed to drop it in.

Anything imperative that I am leaving out here?

 

yup you will need a small tube of ta-29. ta 29 is grey silicon. dont not use any other color silicon. apply only to the "t" joints