First instance we found that the high pressure oil pump had gone out. While we were changing we installed an oil cooler as well. Truck ran fine for about 500 mile and as we were coming off of exit truck died and will not sart. We had access to a scan tool and found no codes. We changed the ICP after seeing 70PSI thinking that was it. We change and got a 200psi reading. We took out the IPR and checked the screen. Was a little dirty..We cleaned and check. Seems to be working.
Some 2003-2007 F-Super Duty, 2003-2005 Excursion and 2004-2010 E-Series vehicles equipped with a 6.0L engine may exhibit a runs rough, lacks power, hard start, no start concern with or without diagnostic trouble code (DTC) P0611 code or various injector circuit codes. This concern may be caused by a DC-DC converter located in one half of the Fuel Injector Control Module (FICM) or by the main circuit board in the other half of the FICM.
Note: Never replace the high pressure oil pump due to debris on the IPR valve screen. Remove the debris and retest the system.
Note: Higher oil temperatures are more effective for diagnosis of high pressure oil system leaks.
Note: To maintain command of the IPR valve while cranking the engine, it is necessary to disconnect the crankshaft position (CKP) sensor.
Note: Make sure the battery voltage is greater than 12.5 volts at all times throughout this procedure. High pressure oil pumps will not pass the high pressure oil pump tests if the battery voltage drops below 12.5 volts during the procedure. The high pressure oil pump is dependent on cranking speed to generate sufficient injection control pressure. If the battery voltage drops below 12.5 volts, the battery may need to be charged or there may be a charging system concern, refer to the Workshop Manual Section 414-00, Charging System, Symptom Chart to continue diagnosis.
The purpose of this test is to isolate the branch tube assembly and the high pressure oil pump from the rest of the high pressure oil system, and to verify pump function.
No or low oil in the system, system leakage, damaged IPR or high pressure pump could cause low pressure.
If the minimum ICP specification is achieved, a leak in the high pressure oil system is suspect. Remove both oil rail plugs and head tubes (stand pipe front plugs and both stand pipes) from the oil rails, as equipped, and inspect the seals as a possible leak source. Replace the damaged components as necessary. Refer to the Workshop Manual Section 303-01C, Engine. Carry out the High Pressure Oil System Air Pressure Test in this section to verify the repair.
If the minimum ICP specification is not achieved, a leaking rear engine tube assembly or a damaged high pressure oil pump is suspect. Remove the pump cover and inspect for leaks. Repair any leaks and repeat the test or replace the pump if no leaks are present. Refer to the Workshop Manual Section 303-04C, Fuel Charging and Controls, Oil Pump.
If the minimum ICP specification is not achieved, a leaking rear engine tube assembly or a damaged high pressure oil pump is suspect. Remove the pump cover and inspect for leaks. Repair any leaks and repeat the test or replace the pump if no leaks are present. For E-series vehicles, refer to the Workshop Manual Section 303-04D, Fuel Charging and Controls, Oil Pump. For F-Super Duty and Excursion vehicles, refer to the Workshop Manual Section 303-04C, Fuel Charging and Controls, Oil Pump.
Note: An air leak on the high pressure oil pump shaft lip seal is normal while carrying out this procedure. This is not an indication of a high pressure oil leak and the high pressure oil pump should not be replaced for this condition. If the pump is suspect, carry out the High Pressure Oil Pump Test to verify the pump generates sufficient pressure to start the engine.
Note: The replacement parts may leak if all the surfaces are not oil saturated under system pressure and the seals are not correctly seated during installation.
Note: Never replace the high pressure oil pump until all high pressure oil system leaks have been repaired and the high pressure oil system is retested.
Note: A complaint of engine stalls followed by a crank no start while the engine is warm indicates a leak in the high pressure oil system. This may or may not be accompanied by DTCs P2290 or P2291. Follow this procedure to isolate the leak.
Note: If an intermittent no start condition or delayed ICP pressure rise during restart after a 15-minute soak exists, a small leak is suspect. Refer to the Hard Start illustration of the previous test. Remove the valve covers to inspect for leaks.
The purpose of this test is to verify IPR valve operation and to isolate leaks in the high pressure oil system.
Note: It is easier to find small leaks with higher pressure.
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