Good afternoon FTE, I am looking for some help with my truck. My 2001 F350SD 7.3 6speed manual 4x4 has been having some issues recently and I’m currently at a loss at to the fix, so I’m returning to the forums for assistance. A while ago my non serviceable bolt on my HPOP backed out and caused the truck to shut down, so I rebuilt the HPOP with a rebuild kit from Thoroughbred Diesel. I then put the truck back together and got it running, but when I plugged in my ICP sensor is was surging, the engine would defuel, and it would over boost like crazy. I unplug the ICP sensor and it runs fine, but with a CEL illuminated and with stock power. I then ordered a new sensor from Ebay, got it put it in and nothing, no start after replacing and plugging it in. I unplug it and it fires right up, I let it run and plug it in and it kills the truck, so I request my money back from Ebay, they oblige. I put and old sensor back in plug it in, it starts but it is surging again with high boost and defueling. I compiled the money to order the stock one from Riffraff diesel, I get it , put it in, and it is surging up and down at idle minimally but still surging, as well as lagging throttle response, once the throttle responds the boost is slow to respond. If you try to drive the truck it drives fine for about gears 1-3 then once it gets to 4th gear it will overboost, then when you let off the throttle it defuels big time, and throws a CEL. If you attempt to drive in gear at a low speed it’ll at like I just learned how to drive manual, bucking up and down and jerking until you downshift. When you get to a redlight with the CEL illuminated and the engine defueling it sounds god aweful until the engine finally realizes there’s no throttle being depressed and finally calms down after a few minutes. If I unplug the sensor it runs just fine, no bucking, no surging, and no overboosting. What am I missing or what could be wrong? I do have an obd scanner with FORScan so if there’s something I need to look at in the computer I can, but I need help with this because it’s so annoying and expensive with all these sensors being replaced.

 

I forgot to put in the post that the truck has a bully dog obd plug in programmer and a Thoroughbred Diesel plug in boost fooler. The IPR has already been replaced as well, but that was a while ago from Ford (expensive). Another thing I did was put in the oil crossover line from head to head from Thoroughbred Diesel and ran stiction eliminator from Archoil through the system, which helped with diesel engine tick but I feel like made the engine surge worse when I plug in the IP sensor.

 

The trouble codes might be helpful. My first impression is a sticking IPR valve, but that's just a hunch.

 

No problem, I can get them in the morning and post them back here. Would the ipr be able to be cleaned or would it need to be replaced if it is sticking?

 

Good morning everyone, got the codes for you, P1280,P1249,P1211, and P1139.

 

Some bad news for everyone here, gonna be a little while before I can do anything with the truck. Took it to get fuel this morning and ended up blowing the front HPOP line out of the aluminum, so now I’m going to try to helicoil it when my kit arrives, hopefully this works and I don’t have to dump money on a new HPOP. I’ve read both good and bad from people doing the helicoil so we shall see. Will post back once I get her operational again.

 

I don't see how a helicoil will work on an o-ring boss port. Unless my memory is failing and those aren't ORB.

 

I was looking online and some people have repaired their HPOP that way, I just called a local salvage yard that I’ve gotten parts from before and they’re looking to see if they have the HPOP on hand.

 

So I scrapped the helicoil idea, my local salvage yard has an HPOP for me they’re selling me for 125 off a totaled truck that came in 2 months ago, I’m going to take it apart and reseal it with new orings and nonserviceable bolt from thoroughbred diesel. Will post back here once completed.

 

Sounds like it could be some kind of issue with the ECM. I'd give that a check. Wouldn't hurt.

 

Good morning Powerstroke nation. It’s been a while since I’ve been here, but I recently reoringed the salvage HPOP, put it in and received the old “no start”. Turns out that the internal swash plate and springs weren’t compressing the oil anymore so I had to come up with a solution for my old one since I don’t have 400 dollars to upgrade my HPOP. I went to tractor supply got an oring boss with jic, rethreaded the hole larger and upgraded the lines to the cnc machined lines. Got it all sealed up back to normal, put it in and of course, no start, killed the batteries trying to start it, so I charged them, tried it and still no start, not even any smoke coming out of the tail pipe. I hooked up my obd tester to it and opened FORScan, looked at IPR percentage, ICP duty cycle, GPR cycle, while trying to start the truck, these are my findings: IPR koeo 14.43%, cranking 64.34%, ICP 400-1200psi cranking, GPR cycling like normal. I watch the oil gauge on the dash and it’s jumping to normal range as soon as I try to start it. I pulled the pigtail off the IPR and it’s getting 11.3 volts from the ecm, ohmed out the solenoid and got 13.2 ohms. What am I missing? Is there something else I should check? Yes it’s getting fuel, my drain line is plugged up somewhere and when I open the line then pull the line off the nipple it sprays diesel everywhere so I know it’s getting pressure, however I don’t have an exact pressure reading to report here for it at this time.

 

IPR should not have to get anywhere near 65% to get the engine to start if the high pressure oil system is properly functioning. You did open up the high pressure oil system multiple times which allows air into the system, but if you get an ICP of more than 500 PSI consistently, enough air should have been purged by cranking that it will at least start. It may take quite a bit of cranking to get enough air out to get the engine to start. I would take your tuner off before any troubleshooting so you have a known quantity (stock PCM) that we are dealing with. You will also want to clear the codes, try to start the truck, and then pull the current codes.

One of your initial codes was P1280 which is ICP circuit out of range low. A failed sensor or bad (open) pigtail to a good sensor won't let the PCM know what the actual injection pressure is and you may have a no-start. Check to see if this code is still current. Do note that the PCM may report some ICP value even if the sensor is bad or disconnected, it just makes up a figure it thinks should be correct to try to get the engine to run as a limp-home feature.

 

What is ICP voltage reading key on? How about cranking? ICP PSI is pretty useless for diagnostics since the PCM will report an inferred value if it sees the sensor as not trustworthy.

 

Good evening, I got home from work and took a short nap. Upon waking up it was raining outside so I waited until it cleared out. I went outside and tried starting the truck, again with no success on the first key cycle, took the oil pressure a minute to build. I let the starter cool off and went to start the truck a second time and nada, no juice to the starter. I feel the starter relay and it’s hot af. I let it sit for about an hour and try to start it with nada again. Unfortunately I’m going to have to wait until I head to work tomorrow to get a new relay, meanwhile I’m going to charge the batteries. I’m wondering if that’s robbing too much power to not allow something to work properly and it not start. Anyhow I’ll be off on Sunday, I’m going to replace that relay and keep yall posted on findings of readings and pressures once I get the relay installed.

 

Alright so it took longer than expected because the truck just didn’t want to try to crank, the parts store gave me a 4 post starter solenoid that wouldn’t send the signal to the starter, I had to go back to the parts store again to get the right one. I put the relay on and cranked, to no one’s surprise, there was still nothing coming out of the tailpipe and no start. I pulled out FORScan again and ran all the koeo tests, the worrisome one that kept popping up is p0380, glow plug circuit failure, tested the circuit with the test light and nothing crossing the relay, I have power on 3 of the 4 legs but couldn’t get the power all the way across no matter what I did. As of currently I still have no start. Also I did get power readings off of the ICP, with key on the ICP voltage is .02, with it cranking the voltage is .17. Could the GPR be causing the no start or am I still looking at the HPOP/IPR? I’m thinking the latter of the two. Also I looked at IPR readings and it climbed up from 14% to 23% to 45% to 64% then stayed there while cranking.