PLEASE HELP ME!!!

truck had low power and then died on the highway. towed it home, it cooled down, and it actually started but had no power and ICP only got to about 600PSI regardless of throttle position.

replaced the HPOP, ICP, IPR, J-pipe, oil cooler, both fuel filters, oil+oil filter, intake gaskets. poured the last 3 quarts of oil into filter housing to help prime the cooler and HPOP. also filled the J-pipe after installed.

batteries were weak, but it finally started this morning. let it idle until all temps were normal, about ~15 minutes total. seemed like it was OK, but i did hear a "hissing" sound from near the alternator area. felt around the turbo rubber elbow for a leak but did not feel anything. it needed batteries so i shut it off and bought two new batteries.

batteries installed and it spins over very well but will not start now. i am losing my mind trying to figure out what is wrong. was the "hissing" sound a clue? no fault codes have been logged since batteries replaced.

i have an ELM327 and TorquePro app. what should i look at to diagnose this issue or issues???

 

Ck fuel pressure, take out fuel filter turn key on a min see if it fills. unplug icp try to start just to see. ck ficm voltage,sync.

 

thanks!
i will pull the topside filter and check for fuel flow.

i replaced the ICP with a new Ford part, IPR too.

FICM voltages are 12, 12, and 48.5.

cam_crank sync=1
FICM to PCM sync=1

the low HPOP pressure, ~230psi, while cranking concerns me; maybe i sprung another HPO leak, maybe??? early 2003 6 liter does not have dummy plugs and uses the one-piece stand pipes that rarely go bad, but maybe it is leaking because of the new pump and better pressure. idk... color me so frustrated. it cranked and ran for ~20 minutes, now no start. photo of Torque while it ran for ~20 minutes, then link to video of the crank/no-start after replacing the batteries.

 

HPOP is a Ford reman?

Did you do the checks that Mark asked about?

Air tested before repairs, and after?

 

pump is a BOSTECH remanufactured with OEM Ford parts. a pump from Ford would have taken too long to receive, plus the lame core policy.

i mean, i had the core in my hand and could have overnighted it to them in order to eliminate the charge, but they said no.

air tested before and after through the J-pipe. before was blowing oil out of the cooler reservoir where the screen goes, after i could not hear any air escaping anywhere.

 

Looks like ipr still high looking at vids,might need to pull and ck screen and see if hung open.

 

possible i suppose, but the IPR i removed has 265K miles on it and i think it was actually OK. i replaced it since the coil could be weak and because it had 265K on it, AND because it is a mother toucher to replace afterward.
how can i tell if it is hung open? if the plunger is stuck???
do you know what the coil resistance should measure on the bench?

 

OHM Test of IPR
IPR TESTING WITH A DVM
. A good IPR should read about 6.0 ohms


Post ICPV and IPR% @ KOEO


you did an oil cooler so that means crap could have blown thru IPR your at the Prime amount of run time that IPR's blow after an oil cooler Not saying that's it but High probability


BUT get all numbers before any teardown

 

A GOOD IPR should also read 14.4% at KOEO this shows what PCM is Comanding it to there is no position sensor in the IPR
A Good ICP Sensor normaly reads .18-.24 volts at KOEO

ELECTRONIC SPECIALTY TESTING INFO
1. IPR
AT KOEO SHOULD READ 14.4%
WITH DVM SHOULD BE AROUND 6 OHMS ANY HIGHER THEN 35 OHMS THEN ITS NO GOOD
-------------------------------------------------------------------------------
ICP volts/psi
.....PSI......Volts

0--------------0.02
200-----------0.4
400-----------0.73
600-----------0.96
800-----------1.2
1000---------1.4
1200---------1.6
1400---------1.9
1600---------2.1
1800---------2.3
2000---------2.6
2200---------2.8
2400---------3
2600---------3.3
2800---------3.5
3000---------3.8
-------------------------------------------------------------------------------------------------------------------------------------------------------------

A HPO PROBLEM WILL LEAD TO LPO PROBLEM

Here is Ford's ssm on the topic:
Ssm 19417 2003-2007 F-super Duty/2003-2005 Excursion 6.0l - Watch For Oil Flow From The Base Engine Oil Pump
Some 2003-2007 F-super Duty And 2003-2005 Excursion Vehicles Equipped With A 6.0l Diesel May Exhibit Low Base Engine Oil Pressure Caused By A Leak In The High Pressure Oil System. If A High Pressure System Leak Is Severe, The High Pressure Pump May Use A Larger Volume Of Oil Than The Base Engine (gerotor) Pump Can Produce While Cranking. If Base Engine Oil Pressure Is Low, Remove Oil Filter, Hold Down The Oil Drain Valve (left Side Of Housing) With A Screwdriver And Crank The Engine While Watching For Oil Flow From The Base Engine Oil Pump. If Flow Is Present, Use The Updated Diagnostics For The High Pressure Oil System (electronic Version Of Pc/ed, Section 4, Step 10e). If There Is No Flow At The Oil Filter Housing Diagnose The Base Engine Oil System First (workshop Manual Section 303-01c).
Effective Date: 10/06/2006

 

full page engine wire diagram
https://www.ford-trucks.com/forums/a...7&d=1485755349

 

if you pull IPR you can see if junk went thru screen if so flush it out


You can also press the plunger with screwdriver it should move very slightly and press while flushing


Search diesel tech Ron vids he shows how to clean IPR out

 

thanks Blade!

so, you are saying that after an oil cooler replacement, the IPR is likely to fail? even if it is brand new???
i will read the resistance of the old one. i replaced the O-rings/screen and flushed it per Diesel Ron just in case i needed it later.

 

while cranking, i do notice the oil pressure gauge on the dash goes to the middle or ~50%. i think this could be deceiving since this gauge sensor is only a 5psi switch.
at this point, pulling the RH valve cover and pressure testing the HPO system is my best bet. ICP very difficult to access and apply pressure there; IPR only slightly easier to access.
i have the ICP and oil rail test fittings. would you agree that is the best place to start? i did not remove the valve covers for this job. given that the HPOP/cooler/ICP/IPR are new, it seems to me that it is more likely that the issue is elsewhere? rails or stand pipes?

 

Blade is saying it’s common to get trash in the IPR screen after an oil cooler replacement. Pull IPR and check / clean screen.

 

Aha! I see, said the blind man!

thanks