Yesterday evening I pulled the PCM to get the codes off it. I reconnected the PCM, then pulled the ICP connector and got it to start. Ran it a few minutes then reconnected the ICP and restarted it. It would idle but occasionally had a 'blip' in rpm increase for a moment. And would idle for a minute or two and die, unless i increased rpm slightly above idle, then it would run continuously. IPR% and ICP pressures appeared normal. With it running the P1283 IPR circuit fault went away, got the P2111 all clear code. Shut it off and pulled the driver side valve cover. The P1283 code returned but I was again able to start it with the ICP unhooked. With the valve cover off and running the only oil splashing is from the injector oil shroud, no leaks around the injectors. The harness looked good. Today i'm going to pull the passenger side valve cover and check it.

 

A/C off? At this time of year it will cycle on and off a bunch. This will make the RPM rise about 100rpm each time.

 

The A/C is shut off, not involved in the RPM or ICP issue.
Update: Yesterday I pulled the other valve cover, injectors all look normal, no loss of oil around the injectors. I've ordered new harnesses and 1 glow plug to replace while i'm in there. I also ordered a new Cardone PCM. I figure that by the the time the PCM shows up in 10 days or so i'll have the harnesses installed.
I hate throwing parts at this thing, but i've got more money than time and don't mind having known good parts if they'll improve and extend the life of the truck.

If it has no leaks internally or externally on the HPOP system, and the HPOP is new, my logic is my low ICP when cranking is an ICP or PCM problem?

 

Your IPR and ICP numbers look good for when the truck is running. I just looked back through some data logs that I have of my truck, and 12% duty cycle idling at around 550-580 PSI is about what I am seeing as well.

The times you cannot get the truck to start, though, I am confident saying that it is due to poor ICP pressure. I forget exactly what the pressure is (375 PSI runs in my mind) but there is a minimum pressure under which the PCM won't allow the injectors to fire. I think you're well below that at the 190-249 you're seeing. So that being the case, there are 3 possibilities: 1- The IPR isn't closing to allow it to build the proper pressure, 2- It is building the proper pressure, but the ICP isn't properly reporting it to the PCM, or 3- The IPR and ICP are functioning correctly and the high pressure system is leaking somewhere allowing oil to escape and keeping the system from building the required pressure to start.

Just to confirm what I recall you saying already:
IPR and ICP are new Ford or International parts since this trouble started
You have Ohm'd the wiring back to the connector at the PCM

If that's the case, it kind of feels like you may be closing in on needing to possibly look at the PCM itself.

The alternative is that you can build a HPO test gauge out of a 2500PSI liquid filled gauge and a hydraulic hose and plumb it into one of the plugs in an oil gallery and see exactly what the pressure actually is. That would tell the whole story, and would be cheaper than buying a PCM. I forget what the fitting is at the head (#5 o-ring boss, maybe?) but if you pull a plug out and take it with you to a hydraulic shop, I'm sure they can match it up and make you a 2 foot hose that you can connect to a gauge. I have done that on my personal truck when I was diagnosing a drivability issue (ended up being injectors) and it works well, eliminating all guess work associated with reading the pressure through the electronics.

 

Update-the truck is still broke. I am waiting on a new PCM to arrive from Advance Auto. In the meantime I pulled both valve covers and replaced both under valve cover harnesses. I've ran it a few times, either it started on it's own or on starting fluid.
On monday it started like nothing is wrong. Ran good for about 30 minutes. shut off, starts good. Then it started missing on one cylinder. IPR% and oil pressure looked normal.
Yesterday it wouldn't start, still low ICP pressure. Started it on starting fluid and it took 54.9% IPR to make 700 rpm.
Will see what happens after the PCM arrives.

 

Found this IPR testing and hope it helps

 

I deadheaded the pump hoses against a guage and determined it was making 3600 psi. Then tested each head at a time and it tried to start with the passenger side oil line plugged off. So I rebuilt the injectors with external O rings and it started. I've driven it two days, about 120 miles and it seems fixed.
I did not find any obvious signs of leakage on the injector O rings but it certainly made a difference. I also consider that it may have had a leaking bypass that sealed or cleared when I deadheaded the pump and forced flow through the bypass. Its a new rebuilt Adrenaline pump.
Thanks for all the advice, I appreciate the help.

 

You must have had a failed oring on the passenger side

The IPR is the only bypass

Good t hear its running again

 

So it's been running perfect for 3 months, till lately. It has started idling rough. Will idle smooth intermittently (578psi oil pressure & 10-11% IPR) but then it has lots of little rpm blips where it speeds up for an instant. On a scanner I can see the rpm chase around, but it is so quick it doesn't really register it. Same with the IPR reading, on the scanner it basically stays they same but you can hear/see/feel the rpm blip up for an instant. It'll do this about 15-20 times a minute.
It's mostly an idle condition, it cleans up over 1000 rpm. It'll blip now and then when driving.
Any ideas?
If you recall, everything is new..
thanks

 

Some of these trucks just do this. I think it's just a product of the electronics and controls all being a 25+ year old design. I wouldn't fret about it at al unless it is really extreme. It's possible to be so attuned to the little details on these things that you start to second guess, making issues out of things that aren't issues at all. At least that's been my experience.