Yesterday, out of the blue, my truck died while driving. No muss, no fuss, it just shut off like I turned the key. Once off, it cranked fine but showed absolutely no signs of life. I sat for 5 minutes or so contemplating the situation, and when I tried to start again it fired up like nothing ever happened.

20 miles further down the road, it happened again. This time it took about 30 minutes, but eventually started right up.

I made about 3 miles and it happened again. I was at my first destination and when I came out (about 15 minutes) it started right up.

I went about 5 miles this time and it died again. After 30 minutes of trying to start with no luck, I had it towed home.

It started up immediately once in my driveway. I pulled it in the garage and shut it off. Hooked up AE and ran the usual tests - nothing out of the ordinary. I started and shut it down 3-4 times doing this. I took it out on the road around town and it died 2 miles out. The KOEO test time returned a P1283 code - IPR circuit failure. I monitored the ICP and ICP duty cycle while cranking and found ICP would not exceed 165 psi. According to an IPR troubleshooting guide I had lying around, this indicates the IPR is likely stuck open.

Everything I've found regarding the IPR sticking open is presented in a hard starting scenario. That's not really what I have - it either starts or it does not. Can the IPR suddenly stick open while driving - causing the engine to shut off immediately - and then unstick itself after sitting thus allowing the engine to start? Or is there something else going on like a wiring issue?

 

This sounds like the CPS is going out. Have you tried changing it? We all keep a spare in the glove box because this is very common.

 

Sounds like the CPS to me as well, however with the crank issue and the proper tools (good on you!) I would pull the IPR and clean it. Reinstall and see if it comes back.

I had the same issue for the last several months, but with my scan gauge hooked up all the time I could tell it was not the IPR but was the CPS. Pushed it until I almost missed my sons shoot at the fair... Changed it the next morning... LOL

 

if you come to find that it is the IPR shoot me a PM.

 

CSIPSD
How did you identify the CPS with the scan guage - code?
Could the ICP sensor be the culprit? It might be worth a try - just disconnect it electrically and see what happens. If it starts and runs then you know.
Ford should have set the system up so that if a code is set for the ICP sensor, then the PCM would use a default injector pressure setting to keep you on the road running.

Good luck

 

Yes, there is a CPS code stored... That and the fact that the ICP pressures were coming up as normal.

There are only a few things that will kill a 7.3 dead... CPS, IPR, PCM and IDM are the normal ones... Everything else will cause runablity issues, but the truck will normally start and run.

The truck does run that way. Try it... Unplug your ICP sensor and the truck will run and drive fine.

ICP sensor will not cause the truck to die.

 

I feel for ya. Just went through the same with my truck. Shop put on new CPS, new ICP, new IPR, new pigtail on IPR and it still exhibited same symptoms you are describing. Ended up with a new HPOP and it runs like new.

Not saying its the HPOP, but if you run through all the above without luck, may be it.

 

I replaced the CPS yesterday afternoon after the truck was towed home. It's not the CPS.

Here is what the IPR solenoid connector looks like. Nice.

 

I was just about to reply with CPS as well since I had nearly identical symptoms and a fresh CPS cured my ill's. Glad you found the problem!

 

That didn't fix the problem, it died again after 4 miles.

 

Thats just the rubber seal. Its not your problem so long as the connection was still good. Pick it out of there and plug it back in.

 

I looked at your profile and noticed you have a 2003 Excursion. Is that solenoid nut still tight on the IPR? Oil level good? Did you unplug the ICP sensor and try to start? Last link in my signature will help you out - particularly since you have AE. Good job!

 

Replaced the IPR Friday, drove 280 miles yesterday with no issues. Problem solved.

 

I would be more then interested to take that old IPR off your hands...

 

It already started a new life as landfill fodder. Sorry.