First off, heres a couple links to another local site I've been posting to. And another thread here Ive been posting to for a guy with another no start issue.
Ford 2003 HPOP vs ICP problems
I just got AE so I can run any tests anyone here thinks is needed. There is also AE test results posted on those other threads. That said, I just got AE..So I'm not that good with it yet.
::early 04 6.0 with 03 motor::
Problem started with a sudden rough idle and a miss along with a pretty odd rattle sound
. I've been through injectors before, it was a different miss than that
. Check codes while limping it to my shop using BD outlook monitor. Had a p2290 and a p0284. Got to shop, turned off, no start, Waited a couple hours, started with same symptoms, drove 1 mile and died. Hasnt started since. Got AE, noticed ICP values were off so replaced ICP. Still no start. Pulled IPR and 12v jumped it. No click no nothing. Replaced it. Same problem.
Can you elaborate on the fields highlighted in bold red?
Then hooked up air to ICP port. Heard gurgle, waited, gurgle, command IPR to 100% w/ AE...NO Change. Gurgle. Seems to be comming from inside motor/ HPOP area.
Did you try opening the oil filter cap? Another fellow Ford dealer tech has confirmed many bad high pressure oil pumps by air testing the high pressure oil system, and hearing air leaks exiting into the oil filter housing area.
:::Question. I've read various threads on doing this pressure test. ie Apply air, gurgle, command 100%, should stop, if so w/ these symptoms, could be bad HPOP. Or, should quiet down, then hear faint leaks, trace to source. Then I read about blocking off some lines or deadheading pump. Can anyone elaborate on the propper procedure for doing this?
The Ford PC/ED test procedure on 2003 engines is to remove both valve covers and disconnect the braided oil rail feeds at the rails, and install block-off tools in their place. By doing as such, you are isolating the injectors and the oil rails from the high pressure oil system. In effect, you are testing the high pressure oil pump output. With IPR duty cycle commanded above 60%, and good strong batteries cranking the engine over, the spec is 1500 psi MINIMUM. Anything less than that, points to a bad IPR valve and/or high pressure oil pump.
::Question 2. When I command IPR, should I hear a click? I dont, old one or new one. Also, at koeo, when I do command 100% my values go from 14.84% to 0%. Is this correct? I would think it would go to 100%?
When IPR duty cycle is commanded to 100% with a scan tool, it should indicate as such on the scan tool data. Why the value is going to 0% is beyond me. What you should hear, is a change in airflow with air supply connected, as you toggle through the duty cycle range, up to 100%.
::Question 3. AE is only telling me what the command to the IPR is, not what the IPR is actually doing right? So if the IPR were stuck, open, closed or in between, is there a way for AE to know this?
Correct. There is no position sensor on the IPR valve to indicate its actual position unfortunately. The duty cycle data you see, is only the COMMANDED duty cycle.
::Question 4. Lets say the IPR & ICP are fine, they are brand new after all. Then why no click when commanding? PCM? How would I check that? AE? Or can I pull pigtail (see photo at ps.org link above. both pigs replaced, more info in a min) to the IPR and test the contacts? red to positive contact and neg to battery negative? Then compare un-comm to command values?
You can only test the ground side of the IPR valve circuit (yellow with red striped wire between IPR valve connector and pin #2 of the middle PCM connector). The red wire is a fused HOT IN RUN circuit, meaning you should see 12 volts when the key is in the RUN position.
The pigtail to the IPR was charred and wires exposed at the connector. see link above for photos. Could this have shorted and fried PCM?
If the wires were to short out to each other, the engine wouldn't run PERIOD. If you are still able to communicate with your scan tool, chances are extremely slim that there's anything wrong with the PCM.
Lastly, yes, everything else checks out. Got fuel, got oil, batts are good etc.. Its not the FICM. I'm getting 150-250 sometimes 450psi durring cranking. I KNOW, 03's are famous for HPOP's. I'm trying to rule out everything else first. I'm quickly becoming not only more knowledgeable about these 6.0's but at the same time, I'm falling into the "throw parts at it till it works" catagory. The place I didnt want to be, thus my purchase of AE.
It pretty much looks like a new high pressure oil pump is in your immediate future with what you're describing so far, in this paragraph.
Ok, one more question.. This is my 1 dumb guy allowed limit..
What is the black oval shaped thing on the passenger side right behind the battery? See photo below.. Just noticed this while I was doing a 50th over (vs. a once over..) and it dosent look good?
That is the vacuum reservoir, that stores vacuum to operate the mode selection for your climate controls, and for your PVH (Pulse Vacuum Hubs) if equipped with ESOF (Electronic Shift-On-The-Fly) 4x4.
Thanks in advance for any help. And big thanks To Mchan for helping me get this far!!!