2003 Low ICP Pressure - Ford Powerstroke Diesel Forum
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Old 06-30-2012, 10:37 AM
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2003 Low ICP Pressure

Background:

2003
110,000 miles
No tuners, all factory parts.
Has slowly been running worse for the past 3 months.
I finally decided to tear into when it had a hot start problem.

Found ICP sensor leaking oil, replaced sensor and pigtails for ICP and IPR.
Both were soaked in oil.

Performed air test and heard air from passenger side valve cover. Removed cover and found two injectors leaking from top seals, and air leaking from STC fitting at oil log on top of injectors. Replaced o-rings at top of the injectors and the stainless braided hose.

Re performed air leak test and had no leaks, other than very faint noise from shaft seal of HPOP.

Load tested and replaced bad batteries. Checked FICM power, it never dropped below 47 volts.

Truck will now start every time when it is hot.


Current issue:

The truck has very low power. With trans in park and revving the engine the ICP pressure has no problem hitting 3000 psi. In gear and driving it will not build more than 1200 psi. If I press the pedal more than 25% the truck slows down and starts to let a small amount of black/grey smoke out of the tail pipe.

I removed the IPR valve and the screen is intact. There was one small speck on metal on the screen.

I think the only thing left to check is if the IPR is getting signal to build full pressure. Is there any way to use a multi-meter set on duty cycle to see if it is going to 85%?

I would hate to replace the HPOP only to have the same issue.

Anything else that I need to Check?

Thank you for any help.

-Bobby
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Old 07-01-2012, 07:40 AM
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maybe this

I had the same problem...did you have the turbo off?...if so, it has to seal perfect or it will do this...it took me 5 times and then a new clap to fix mine...also check the CAC pipes for any leaks....if not you may have a HPOP leak...can you check the ICP readings with a scan tool?
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Old 07-01-2012, 08:12 AM
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a scan gauge II will help with the problem it picks up the ipr and icp but i think it is a exhaust leak too try that first
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Old 07-01-2012, 09:15 AM
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There are no sounds of exhaust leaks, and no black soot around any connections.

Will a bad HPOP still produce 3000psi when the truck is under no load? - i.e. in park and revving.
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Old 07-01-2012, 11:05 AM
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my 2cents

If the HPOP is leaking your PSi wil not be that high...when mine went it would only go to like 1400psi...with 3000psi the truck should run fine.....it is hard to tell if the Y pipe to turbo is leaking because you can't see the bottom and it dosen't always make a leak noise...it has to be perfect, I would have bet my house it was clamped right, like I said I tried to re-do the clamp like 5 times then got a new one......go buy a new clamp and rule it out ...$35 from ford....when this happened to me I pulled my hair out for a week trying everything, even bought the AE scanner to tell me nothing....I got a new clamp and had my buddy prying the pipe toward the turbo from underneath while I tighend the clamp...PITA...but that is what it was and what you are discribing is what mine was doing to a T....just my 2cents...good luck...$35 bucks is better then $700 fo a new HPOP.
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Old 07-01-2012, 08:01 PM
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Your IPR valve is an actuator that is controlled by the PCM supplying constant, fused B+ through the red wire with the key in the RUN or START position, and duty cycled ground through the yellow with red stripe coloured wire. It COMMANDS a given duty cycle based on other inputs to the PCM (APP for example) under various engine operating conditions. If you can monitor ICP psi actual and ICP desired along with IPR duty cyle % under the conditions when your ICP is too low, it will tell you most of what's happening. In answer to your question, the only way to verify the IPR is functioning correctly is either to swap in a known good IPR from another '03/'04 truck to "try" to see if it corrects the condition, or do a high pressure oil system air test. Supply power and ground to the IPR to close the valve to see if the air sound changes. I realize and appreciate that it is a royal PITA to air test a 2003 engine, and quite frankly if it will increase to 3000 psi at WOT in PARK or NEUTRAL but fall flat on its face under load under points squarely at a weak HPOP.

As far as others suggestions regarding the y-pipe, I highly doubt that's your issue because it would be very obvious if you had a leak.
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Old 07-02-2012, 12:49 AM
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i'd agree, i'm a master tech as well, and i can tell you that you just saying it is an 03, means you probably need a new pump. and if you did have a turbo leak big enough to have that kind of a lack of power, you'd definately hear or feel it leaking.
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Old 08-06-2012, 09:34 AM
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Quote:
Originally Posted by strokemyego View Post
i'd agree, i'm a master tech as well, and i can tell you that you just saying it is an 03, means you probably need a new pump. and if you did have a turbo leak big enough to have that kind of a lack of power, you'd definately hear or feel it leaking.
The pump could be bad even though it makes pressure? I am having a similar problem. no power past 25-50% throttle, the motor bogs and seams like it has to catch up with itself and blows some black smoke. Starts and idles fine. IPR pressures seem to be in line with specs I have found on the forums. I have'nt bothered to check extensively for exhaust leaks as I don't see soot or hear anything crazy.

Could someone in the know give a rundown on possible causes of low bad top end power, poor throttle response and black smoke? I know it could be a dozen different things bu I think I checked them all! Trying to think of what I missed.
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