TRUCK SUDDENLY DIED - LEAVING ME STRANDED

[FuddleyPJones]

Hi guys,

I'm back with yet another starting issue. My truck has been running fine since my last repair to the HPO system but today - out of the blue it just dies and will not start. Worst of all it is in a Wal-Mart parking lot and I have to get it out of there. I had a 15 mile drive into town and had been to a few other places before going to Wal-mart. I noticed that it was hard to start but a second try was sucessful. I put in gear and pulled out 10 feet and it died. i pushed it back into the parking space and started simple diagnosis.

Here is what I have done so far.

1) Engine will start breifly with shot of starting fluid injected after airfilter. (My thinking was that if it was a slow HPO leak like I had last time the higher revs of the engine will overcome the leak and fire the injectors)

2) Fuel pump humming and bowl at engine filter is filling with turn of key.

I have been reading up on issues here and I am gonna need to read any codes that may be there as well as look into the ICP and IPR but dont know which to do first or if there are other issues to consider.
Thanks for your help.

[Rmorgan711]

hope its not the pump again ..i'm on my 2nd @ 120k

[diablos30]

you dont mention what year truck or the other hpo issue, so im just going to guess that the stc fitting took a dump.

[FuddleyPJones]

I have a totally stock 2004 F350 Crew Cab, Long Box.
At about 96,000 miles it was difficult to start when hot. The HPOP failed and it was replaced under warranty. The guy told me that I was lucky as the repair would have run over $3500. I told him I would have had to sell the truck to pay the bill!
About 8 Mos. later it started doing the same thing - but it was out of warranty...I didn't want to take it to the dealer if it didn't have to do with the previous repair as then they would have me by the nads. I ended up tearing it down myself and replaced every o-ring...I would have found the issue sooner but the guy I had helping me did not follow my request to find and replace EVERY o-ring. He didnt check the ones the dealer put in at the HPOP area. Turns out it was one of those. The dealer screwed up and pinched the o-ring under the HPOP - half of it was flat as paper. Anyway, after I fixed that and cleaned the turbo everything was fine. Until now.
I know the part your speaking of regarding the stc fitting. I noticed it was a crazy design when I was in there. is it normal for them to fail so fast?
I'm gonna try to pull some codes if I can borrow a reader but I really need something more. Before I go blindly into the HPOP area I want to investegate the the other options.
For what its worth, I pulled the EGR valve and man was it dirty! I mean some surfaces had 1/8" layer of soot. I cleaned it but what else should I do while its out? Is there a way to clean inside the Intake manifold without hurting anything?