2003 SD KR 254,xxx Ford replaced engine at 90,000. DELO synthetic Oil changes every 5K. Replaced all injectors with Motorcraft 30K or 2 years ago. ICP failed 2 years ago. Tow a small 5th wheel. Towed 300 miles this weekend, ambient temps 98, Temps 224 and 205 from Edge Insight. Not towing 198 and 190. Early build 03 Motor. FICM by Ed 4 years ago no more problems, still to this day carry a spare......never needed after he fixed it. She surges occasionally at stop lights but I live with it.
Wife took off drivers tow mirror after we got home, I failed to push back in from being extended for hauling, not related just laughed are kidding me. She felt terrible and certainly did not do it on purpose.

Got in her this morning crank no start, mmmmm. Let sit cranked started. Drove it 400 feet to shop. Pulled codes
P0275 Cylinder 5 Balance
P0404 EGR yep still have it because my cooler is an original early build and reportedly has a low failure rate and works just time to clean again
P0480 Cooling fan malfunction
P2291 IPR (suspect this is my real problem)
P2623 IPR open circuit

While I realize I could do all kinds of stuff, I suspect I have a bad IPR and possibly a failing injector.

Thoughts before I go further?

 

Likely a bad connection or a stuck/bad IPR.
For starters you should take it out and inspect the screen, see if it moves freely.

I think it should ohm out around 6

Fix the IPR problem first and clear the codes, then see if #5 comes back.

 

I started looking for replacement IPR, since it is an early build 2003 6.0 it appears it uses a different IPR?
Can anyone confirm and or provide part number. I plan on using OEM.

 

https://parts.autonationfordwhitebea...a/?parent=1075

This would be the one you need.

Check with Ed at ficmrepair.com first, he might be about the same money and a day quicker

 

I've looked for an 2003, it depends if you're getting OE or Motorcraft, and I'm not sure if there is a difference.

 

I don't know there actually is a difference Jack, apart from the screen,
From what I have read the early build had a 200 mic screen, later builds a 150.

There is a price difference to be sure, but I have read many threads of folks that interchanged them with no issues.
The only IPR rebuild kit I have ever seen or used had the 150 mic screen with the little tri bar style guard across the front, as pictured in a late build IPR

 

Ford updated the IPR screen and added an edge filter


05-07 w/ edge filter
5C3Z-9C968-CA
https://parts.autonationfordwhitebea...a/?parent=1075

03-04
3C3Z-9C968-AA
https://parts.autonationfordwhitebea...a/?parent=1075

 

I forgot about this post.

What I was trying to point out shows in the second image, RockAuto.

Yes, there are different IPRs based on the years, but there are two offerings for the '03 model engine, one a Motorcraft and one a "Ford" presumably "blue box" in my narrative. The RockAuto posting shows the two versions, separated by price. And I was saying that I'm not sure what the difference is between the Motorcraft and Ford label parts for 2003-early 2004. It is a $50 difference.

 

Got it changed, kinda a bear for the first time. I ended up removing turbo to install it. My wiring harness goes around the back of the motor and was in the way, along with the EGR I could not get a straight shot on the installation. My blue tooth camera was a life saver. After removing my old IPR it did not have a screen, using the camera and a hook attachment I was able to pull out the oil ring and screen. Once the turbo was off I was able to get the new one installed.
Truck is starting and running much better.
Thanks for all the guidance and help,
FTE rocked again.