This is a little long, I want to give as much info as possible to help you help me.
The problem started 1 yr ago, https://www.ford-trucks.com/forums/4...highlight=1211 . I don't know for sure what I did, but I have not had any problems until about 2 weeks ago. I searched and found no answers.
Truck has ran good until 2 wks ago when I went to pull onto the Interstate and had no power. CEL flashed and tranny shifted very hard. Pulled codes as soon as I stopped and got 1211 and 1209. I know both are related to the injection control pressure. I pulled the wires off the ICP sensor and checked them. Found nothing. Replaced and ran fine for a couple of days. The next problem occured one night when leaving for work. Cranked fine, had no power like before. I shifted into neutral and turned off, restarted and ran fine. worked well for the next few trips. This was the case for several more days. Seemed to happen every other time I cranked the truck. It would always clear up when turned off and back on. 1211 code kept coming back.
About a week ago, I went to start and it would crank and cut back off within 1 sec. I finally had to hold the pedal to the floor to start. Ran rough until a couple starts/restarts, fine after that.
Got to where morning starts were ok and it idled very rough, almost lugging. After a few starts and stops, it cleared up and ran fine. I even made a few long pulls with boats and no problems after the intial rough running.
Now comes Sat. night, Down Town Charlotte NC, 10:00pm, cold (30) and truck cranks and cuts right back off. This went on for 15mins. Finally got her cranked and had greatly reduced power. 45mph up I 85 in heavy traffic. Tried to take it easy to prevent tearing out my tranny. Got home and pulled the ICP sensor out and cleaned with WD40 and reinstalled. (Small puddle of oil under truck. I'm thinking this may have come from the hard run and pulling just to keep from getting run over) Took it out for a test run. Ran like a raped ape. No problems. Sun. Morning, same as night before. start/stop, started by holding pedal down, very rough running, almost sounds as if only one side of engine firing. Couldn't have pulled the hat off my head. Had to take the wifes Tahoe and pull a 27ft boat trailer in CLT traffic. Then pull boats home from show, She ain't happy, ready to go get a new truck now.
Here are the stats for the problem:
Air temps- 30 to 55
Oil- less that 1500miles and full
Fuel- Canister full and clean Diesel clean in every tank, full tank, Two different tanks and different stations.
Fuel filter- Clean
Fuel pump- I can hear it running
Air filter- 6637 and clean
Codes pulled-1211 several times, 1209 once
All connections look clean and tight
HPOP- Checked oil level after 36hrs of sitting, Less that 1 inch for top.
Boost- Normal, up to 24psi
Engine temp- Normal
CEL- Only when engine is in limp mode. very fast flashes.
Tach- Normal
Speedo- Normal
Low pressure oil- Normal by dash gauge
I have a new ICP sensor comimg from Flea-Bay and should be here this week. I don't know what else to check. Sorry for the long post, I hope some one can help. I don't want a new truck and I want my wife off my a$$ about this.
Thanks in advance, and I will keep all informed.

 

Hopefully the ICP sensor will take care of the prob. if not, look into replacing the IDM. Or it could be a UVC harness is coming loose.


Good Luck

 

Thanks, If the ICP sensor don't do it, then I am lost. What is an IDM and what does it do? Tried to search it and no luck.

 

Here all all of the possible contributors to 1209:
Possible causes:
incorrect oil or viscosity
poor oil quality
gel fuel/no fuel
low fuel pressure
damaged IPR valve
high-pressure oil system leak
damaged high-pressure oil pump
damaged PCM

Need to start checking them off form Top to bottom.

 

I've only seen the 1209 once. It was the first time it happened two weeks ago. I really made the engine scream to keep from getting run over on the interstate. Really slammed the tranny. I have since be able to be a little easier on the engine and tranny because I know to watch for the weak engine.

 

You might need to repair your IPR valve.

Have you seen this?
http://cw-diesel.com/LuxSite/IPRInfo.htm

Pop

 

Thanks Pop. I hadn't seen that. Sounds like that could be the problem. I will try to do that soon. Don't know about that extra deep socket. I will have to look and see what I can figure out.

 

I am saying it is the IPR valve. It is located on the HPOP, which is below the fuel filter housing. Kind of a pain to get to as you need to remove wires. It works in conjunction with the ICP sensor. The ICP senses the pressure, and then tells the IPR (injection pressure REGULATOR) to dump oil pressure or keep oil pressure. With a sticking IPR valve, the truck will exactly as you describe, sometimes it will not run right and sometimes be fine. Another sign is if it is acting up while under power, you let off the throttle rapidly, and the engine seems to stumble on it's way back down to idle, it takes an extra second or two, can mean the IPR. Haven't looked at Pop's link but here is the link to the IPR service.

http://cw-diesel.com/LuxSite/IPRInfo.htm

 

Thanks Pop and Kris. I pulled the IPR and cleaned it, reinstalled all according to the link you gave. All went well, although a bit of a P.I.T.A. Now all is back together and the truck want start at all. Spins good, just no attemp to start. I rechecked all the connections and all seem good. I added oil to the HPOP to get it back to the right level before I started. Fuel pump running, I hear fuel going through the filter and return line. I have the batteries on charge now, just in case they are low. Anyone have any ideas what I may have screwed up? I did pull the top off of the fuel filter yesterday to check for fuel and check the filter, don't think that caused any problems.

 

OK, got my truck started after I fixed my mistake from this morning. Note to self, solenoid first, spacer next, then nut. Cranked good. Seemed all was well until I accelerated hard. Engine stumbled or missed. Run very rough on hard pull. No CEL but I do have a 1280 code (ICP Circuit Out Of Range Low). I checked connections and looked good. Don't know where to go next. Any ideas would be great.

 

Unplug the ICP and take a little drive. It will set a code but it will also cause the PCM to use a default value for the pressure. If it drives smooth it points to a biased ICP sensor.

 

ICP is Injector Control Pressure. Sounds like there's still something with that regulator valve that's not acting right, or the sensor that feeds it the pressure information.

Also, it sounds like you're not getting sufficient fuel, which could also be caused by too-low HPOP pressure.

Pop

 

Thanks Guys, Guess it will have to wait till morning. Pouring rain now and I have to go to work in about 1.5 hrs. I have an ICP sensor coming from e-bay soon. I plan in installing anyway.

 

Oh Yea, Please feel free to offer any ideas or opinions. I will be checking in the morning and would be greatfull for all the ideas I can get. I don't like driving the little 91 S-10 when it is pouring rain and callling for bad weather, or for that matter, any other time I can think of.

 

While you're throwing things at it, I would try my spare CPS as well or at least R&R the one in there just to make sure that was OK. I know the codes point elsewhere but you never with those rascals. Good luck.