Truck quit on me a month ago, low ICP showed up in codes. Finally got it into my shop this a.m., plugged in with AE a couple times the past few weeks and cranked. Got it to start twice cold and managed 2nd time (today) to get it in the shop under its own smoky low-power.

So it's a 2003 +/-190K, ICP is original, HPOP is original. At first I didn't see it in the data but I can see now that ICP-V and ICP pressure do not align, so planning to get one. Here's the question. Since it's Saturday, do I snag the local store's in stock sensor (BWD Brand) so I can get it in later today and retest, or do I hold off till Monday and see about an OEM?

Then, if the HPOP does end up being an issue, I've seen some recent support for the adrenaline unit. In searching, I found 2009 posts with mixed feelings and some recent posts where it's sworn by, not much in between. Anyone care to fill in on who's seeing what in the last 8 years?

Lastly, if I replace the HPOP, what would anyone put on the "let's just get this out of the way" list? 6 of 8 injectors are original, other 2 have 95Kish on them. BP egr cooler installed, replaced turbo last year (GT3788VA), oil cooler replaced a few years ago. Did I miss anything? I will plan on inspecting HPOP cover/oil tube if I get in there.

 

Sensor should be OEM although I think BWD is a fairly respectable brand......it's the flea bay sensors that I have read do not last at all
HPOP........not really much discussion there.....Adrenaline, unless you want to roll the dice and money it that tight. I do think there were some issues with the o-rings supplied from them though, make sure they are OEM IIRC
That said I'm sure a Ford dealer is still going to use a rebuilt OEM if one is in the bay.
Injectors not a bad idea at that point, but that is something you can do later if you choose to do so, however yeah....easier with all the other stuff out of the way if it goes that direction

 

I am on my second Adrenaline, first one had a failure they had never seen before, they took good care of me and the second one has about 30K on it with no problems. I have installed several of these for others and will no longer put anything else in. I had several that I had originally put in OEM remans, all you can get now, and 2 actually never ran, one took three pumps before it would start and only lasted 5K miles before it was bad again and several others that lasted less than 10K. Now it's Adrenaline only.

 

Thanks to you both for the responses. Damn sad the remans are that bad. Since posting I've worn myself out cleaning the yard, and tomorrow I'd like to do some shingle repair on the house roofor. So good enough excuse to stay oem on the sensor...

I'm expecting the HPOP to be bad at this age, though I'm crossing fingers that it could have another month's life left in it. I'll be off work the last 2 weeks of May. I was already considering replacing injectors (and more) then just due to age and gut feeling on performance degrade the past year or so.

 

ICP is desired, ICPV is actual... Why they may be off slightly. Go Adrenaline for sure, use OEM o-rings on the
j-tube.

 

Glad you mentioned the J-tube. I meant to ask, does its removal require the disconnect tool on a 2003? I own an IPR socket, any other tools I may want before diving in?

 

I don't know about the tool, heard you need it, but I don't have an 03. Someone will answer that question.

You do need the Ford RTV for the cover or it will leak... don't use a cheap brand. The cover should go on tight, very tight. Several here have used the provided o-ring and had to go back with an OEM to correct it.

 

If you have a die grinder collet tool or something like that odds are it will work. I don't know the size but many guys here have gone that route, it's about the same size.....or just buy one. They are not that spendy.

If you do replace the injectors, it's Ford remans ONLY. There are countless threads here of folks that ended up with nothing but grief going another route. Not worth rolling the dice to save what sometimes amounts to a few bucks per stick. Just not worth it.
I'm not saying remans don't go bad, but by FAR are the best choice unless you are building a street rod and making big HP

As Randy says, use the Ford stuff.....TA 31. Comes in a smaller looking size caulk tube. It's way more than you will use for the job, that is because it's the same stuff used for things like oil pan jobs. It's the ONLY way to go, you don't want to go back in for a cover leak because you saved a few bucks on a cheaper brand. It's happened before

Cover should fit pretty snug going down on the top o-ring, yes. Just be sure to lube it up good as you would on any other install where you don't dry fit something.

I would also stress, don't mix up the top and bottom o-rings, it's an easy mistake to make and the result is you will be taking it back out again in short order.

 

These guys nailed all the important points so let me just add my +1 to them as been there, done that.

Use the Adrenaline pump.
Do *not* use Adrenaline's o-rings
Use the TA31 RTV for the rear corners of the cover.
Pay attention to which o-ring is which so you get it right the 1st time.

Some "while you're in there" stuff.

If you're rich, there's an updated pump cover that apparently reduces the frequency of j-tube oring failure. It's stupid expensive, I didn't do it.
Updated turbo drain tube
Updated turbo feed tube
When was the last time your oil cooler was done? You're going to be right there.
There are some little brass valves in the bottom of the oil filter housing that are also involved in the oil cooler loop which wear out and lead to higher oil temperatures/deltas; they're cheap and you're going to be in there.
Inspect and clean or replace turbo unison ring.
CAC boots in good shape?

I wouldn't slap injectors "just because" personally because they're kinda pricey, they almost always simply deteriorate in a non-critical way rather than suddenly flat-out die, and they're easy enough to get to directly that I don't think there's all that much labor to save yourself from to justify the cost.

 

As I found out. There is another issue on the 03. The HPOP cover rubs on the j tube and can rub though the tube causing a hpop leak. There is an updated cover, but I use a die grinder to remover a small amount of metal from the cover.

This is an updated cover. you can see the camel hump.

2003 Ford 6.0L powerstroke F250 F350 cast iron HPOP cover | eBay

I too wanted the Adrenaline pump. Just did have the extra money to buy it. I did get lucky with ford reman I put in 4 yrs ago.

Removing the j tube can be do with 2 screw drivers, but the tool will make your life much easier.

 

Thanks for the multiple callouts on TA31, that'll save some digging. And for the replies on the tool. It really gets confusing learning the differences from posts and vids in that specific area for early/late fittings. Pump=easy to tell, STC=easy enough, rails, easy. How they go together, gotta get hands in there...

Looks like I've done decent homework. The cover I've seen, planned on inspecting for rub, clearance the cover if needed. Updated drain tube installed several years ago, did it while replacing the oil cooler. Not many miles per year these days and deltas are staying put with about an 8 degree average. The feed tube I purchased while swapping in a turbo last year, but didn't install. Can't recall this moment the difference in the early/later builds that prevented the install...I'll look that back up to see if it's worth it this time.

I'm seriously torn here. I'm confident at least 1 is in need of replacement, I've just put off the diagnosis thinking I was going to dig in next month...I don't know if I need 1, 2, or all 8, but 8 may or may not leave me better off in the long haul. How many injectors go untouched way beyond 200K? On the other hand, I really want to pull the motor soon to replace the oil pan, but I know I can't justify the time this year. So again, torn...

While I'm on that subject, anybody have experience with 6.0injectors.com?

Did some thinking overnight. Think I'll go ahead and order an ICP and adrenaline HPOP, along with disconnect tool (too cheap to not add to the collection), TA31, and O-rings. If ICP is all it takes to run, I'll reassess and dig in the rest as planned next month. Either way, I somehow missed reading about the early HPOP's being so crappy. I'll replace that time bomb either way.

 

For the ICP, buy one for a 05 with the repair pigtail. It is a better and mine hasn't leaked since I put it on 10 yrs ago.

 

One simple check to see if your ICP is acting up, simply unplug it. PCM will just use a default number. Won't hurt anything doing this. If this is your only problem then should start up fine hot or cold. If the pigtail is soaked, that needs to be replaced as well.

 

Noted, thanks. I haven't put hands on the ICP yet, but I'm pretty sure I saw the end of it looking oily by flashlight. That's how, on top of crazy readings, I figured I'd just replace it in one step. Was going to wait and see on the connector, but that's too cheap to leave off the list. I really want a good ICP in before doing anything else so I can see how sick/healthy the rest of the system really is.

The wake up call is definitely in place though, HPOP replacement as I said is just a matter of this month or next. Not going to chance waiting till I have the family loaded up with a camper in the bed and the boat behind us...

 

It's been a busy month, truck work aside. Replaced ICP with OE, went with base Adrenaline HPOP. Was hoping to replace ICP and crank it before digging in deep (pure curiosity, it wouldn't start with ICP unplugged) but present tools did not allow for it.

So all that just to say thanks again for the thoughts, it's running again. Now on to chasing the P132b that wasn't there. No comments needed, I haven't had time to begin, plan on plugging in later today to start narrowing it down.