-Reposted this to the proper Late 7.3 Forum
Vehicle 1999 F350 7.3 450,000miles
The jist of it:
Truck died on the highway with little to no ICP pressure
Swapped parts store IPR and it failed to build pressure to start
Returned part and received a new one and installed, it seemed to work for 20-30min then suddenly it stopped running while driving. After removing, found that it had disassembled itself in the engine. Luckily it just unscrewed and all parts were contained. Part returned and I got my money back.
I purchased a Motorcraft IPR from JeliBuilt Performance and installed and the truck runs now but dies after a 5 minute drive.
Some More Details:
With a Motorcraft new IPR valve the truck runs but if I drive down the road the truck will die and then after some minutes it will restart. Watching ICP sensor pressure it is high, over 1,500psi with IPR at 4.9%. Unplugging the IPR the truck will still run(Yes the regulator at the bottom of the HPOP and not the ICP). Using a 4,000psi mechanical gauge it follows the the ICP pressure sensor readings. Installing an old gutted IPR the truck will not run. Installing another IPR that I have that is used, the truck wont run with the IPR unplugged but will run with it plugged in. It seems that the ICP pressure reading increases as the engine warms up regardless of the ICP being plugged in or not (When using the mechanical gauge I use the ICP port). I am waiting for fittings to run the ICP and mechanical gauge at the same time.

I pulled the Engine harness and replaced a few pigtails as I questioned the IPR pigtail. Purchased an Alliant pigtail, nice part!

My truck has high mileage and blow-by. Running new injectors, and new turbo with JeliBuilt Performace tunes on a Hydra. Smokes a bit out of the exhaust(I accept this fact as miles are 450k). Oil does seem to get dirty fast.

Toward the end of working on it yesterday I thought about what I worked on during this process and I think before I installed the Ford IPR valve I changed the oil. Normally I'm a Rotella T4-T5 guy depending on the price. This time I bought Valvoline All-terrain 15-40 HD diesel oil as my local Napa had it dirt cheap. I like Valvoline on all my gas stuff. Out of the container everything seemed normal. But after little to no miles and idling, oil seems thick and it is black already. Maybe 10 miles on it during this whole process. Could the oil be too thick and causing me issues by restricting the return? First time using this oil. Doesn't look like water in it(no cappuccino) and doesn't smell like fuel.

Sorry for all the info, just wanted to make sure I had more details, I hope someone has seen something like this and give me some ideas.

 

Yeah, I suppose it's possible not all oils are up to the task of the HEUI injection system. I checked the list of oils approved by Ford for Powerstroke engines and don't see a single Valvoline oil listed. You can send a sample off to Blackstone for testing or just change it to one from the list. Surprisingly there are several discount/store brand oils on the list to choose from too. I linked it below.

https://www.fcsdchemicalsandlubrican...SSM2C171F1.PDF

Edit: Whoops I did find a Valvoline oil on the list, the NextGen HD and a couple All-Fleet flavors. No All Terrain though.

 

Thanks for the quick response. Want to see a few people's response to see if there is something else too! Heading to the store to get oil soon and test this out. I miss my big turbo noises! 😭
Nice to bounce ideas off of people to see if I'm crazy or not. If anyone wants ForScan data, I have that too.

 

Yes, load the data. It could help a lot.

 

I don't really see oil being the issue. Unless it's as thick as gear oil or something crazy. Check hpop reservoir and make sure it full of oil.

 

Can you post a FORScan log of ICP, IPR%, RPM, FUELPW, MFDES, and any other PIDs you'd like? At idle, and any running/driving time you can get out of it before it dies.

I don't understand how the engine can run with the IPR valve disconnected, unless the valve is stuck partially closed to allow the HPOP to build at least 500psi. Not sure I trust any of the IPRs you have installed yet. 4.9% IPR and ICP over 1500PSI tells me the PCM cannot regulate the HPO low enough with the IPR installed. I'd expect 9-12% and 475PSI at warmed up idle on stock injectors.

What are you using to look at engine parameters? Any codes?

What is your fuel pressure?

 

Icp unplugged value does increase with rpm. I think this is intentional or as designed.

If I remember correctly the lowest icp value unplugged at idle is 1350 or around 1400.

Is the icp sensor new Motorcraft? I've had one fail that read false high. It effected performance, it was a dog.

 

If the reservoir was low I wouldn't be building pressure....

I don't trust any of my IPRs either! Thinking stuck or restricted. But watching the pressure as it warms up you can watch the ICP pressure slowly build to over 2k and same if using a mechanical gauge.
Not stock injectors, Full Force 1.5 180 30%
Fuel pressure 60psi regulated return and mechanical gauge in the engine bay.
And I've got all kinds of codes 1280, 1209, 1211
Running Hydra, Edge Products and a laptop with ForScan



It's a parts store ICP sensor but since it matches a mechanical gauge I'm fine for now. Once it fails, I will put a Motorcraft one in.

 

And I know pressure increases with RPM, but all my testing above was at idle. Over 2000 psi at idle.

 

So you have confirmed its building hpo pressure when it dies and will not run?

 

..... Didnt think to try that.... I'll check it out tomorrow

 

That's the time when I was referring to check the hpop reservoir and make sure it's full when it dies and doesn't run. But check for pressure then as well whole you got gauge on it.

 

Uploaded some new runs here from today. I drove it down the road and it didn't die but the pressure was thru the roof again after the engine warmed up. Usually it doesn't let me get home but I managed this time somehow. This whole run I had a mechanical gauge attached to a port under the solenoids on the valley and I monitored the HPOP pressure and it seemed to read within 100psi of the ICP sensor. MAP pressure doesn't represent true boost pressure as I have an inline tool that allows me to run more boost with making the ECU go crazy.
I have been running this setup for over 2 years now with no issues other that my blow-by getting worse at 450k.

Thanks for the help thus far.



This is the picture of the High Pressure Oil while idling during the ForScan run named "pic"

 

Looking the data over now. One thing that would help me is if you can select all the PIDs in the FORScan Q&A thread. Some of the PIDs you have in these files are not supported on the 7.3, and not providing useful data.

FORScan/FORScan LITE Class and Q&A - Ford Truck Enthusiasts Forums (ford-trucks.com)

 

Thanks, I only added ones you suggested. FYI I have a ZF6
​​​​​​