Help With Interpreting AE ICP Results - Ford Powerstroke Diesel Forum
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Old 04-15-2013, 06:26 AM
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Help With Interpreting AE ICP Results

Hello Guys,

Sorry in advance for the long post but I wanted to provide as much information as possible. I have been having a random hot no-start for the last few months. I have had two different diesel shops look at it but they could not find anything wrong. I finally broke down and purchased AE. After reading through what seemed like a gazillion posts on this site, I have never seen a thread where the problems were the same as mine. I have seen some that were close but every time, the threads seem to just stop with probable problems and the OP never came back with a fix. My plan is to post results of my fix in hopes that it can help others with their 6.0L problems.

Truck is a 2005 f250 6.0 with 51,000 miles. All stock to include Motorcraft filters, I run Opti-Lube at every fill-up, new batteries and I donít think STC fitting has been replaced (bought used). My problems started about 1 Ĺ years ago when the truck would randomly shut off when letting off the throttle. This problem progressively got worse and I took it to a diesel shop that had for 3 weeks. They trouble shot, swap parts from other known good parts and reported back to me that it was a bad PCM. I questioned how they came to that conclusion and they stated ĎWe have swap out all other parts so it has to be thatĒ. They wanted $2100 to install a new PCM (this included their diagnostics). I didnít think that was my problem and told them to put my truck back together and I was coming to pick it up. When I picked up my truck (after paying $1200 in diagnostics fees) I have never had the problem anymore.

Fast forward to about 6 months ago, I started having hot no-start issues. Took it to a local diesel mechanic who has a good reputation for 6.0Lís and ask him to look at the truck for the hot no-start condition. He had it for a few days but could not re-produce the problem and said the HPO system pressures looked good. He didnít charge me anything and told me to bring back when it broke and he would charge me when he fix something. Great Guy!!

So now, I am having cold hard-starts and hot no-starts. It runs great when it starts. I donít drive the truck that much simply because I donít want to be stranded. But now that the weather is getting warmer I need to tackle this problem. Yesterday I took it out for a good drive and when I got back, I shut it down for about five minutes and try to re-start it but it would just crank and wouldnít start. I hooked up AE and recorded my attempted starts. The average results during cranking are as follows;

ICP Desired Ė 652 PSI
ICP Volts Ė 0.28
ICP Regulator (IPR Duty Cycle) Ė 84%
ICP (PSI) Ė 34 PSI
FICM (Main Power) Ė 47.5


Iím fairly certain that I have a major HPO leak with my IPR duty cycle getting up to 84% and my ICP pressure only building to 34 PSI. What Iím not sure of is if it could be my IPR stuck open or itís a leak in the HPO system (STC fitting, dummy plugs, stand pipe o-rings). Based on my results, what do you guys think?

Iím getting to the point to just tear into this thing myself and replace all known problems (including Bullet Proof EGR Cooler and a new Oil cooler. I have also attached the Excel file with me AE results. Start attempts are highlighted yellow. Let me know what you guys think.

Thanks for your help!!!
Attached Files
File Type: xls AE Results.xls (46.0 KB, 30 views)
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Old 04-15-2013, 08:38 AM
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Quote:
I’m fairly certain that I have a major HPO leak with my IPR duty cycle getting up to 84% and my ICP pressure only building to 34 PSI. What I’m not sure of is if it could be my IPR stuck open or it’s a leak in the HPO system (STC fitting, dummy plugs, stand pipe o-rings). Based on my results, what do you guys think?
You have to determine if it is the IPR not closing (remember the duty cycle position is only based on voltage, not the actual position of the valve), or if your HPO is a leak that is finally getting noticeable (STC or other o-rings) or pump that has finally given out.

Your ICP volts need to be 0.8v (500psi) for a start. Often you can get 1500psi on a slightly longer crank. A warm happy engine will fire off at 500psi.

Since you didn't tell us the year of your truck, how you set-up the air test will vary. The ICP port on later years is easy to do. The early ones require you to take off the valve cover. You will require a M12x1.5 adapter into what-ever you plan on using for air.

Since you are more than likely going to have to tear into it, a first step would be to confirm the integrity and correct operation of the IPR. First in the vehicle, and after on the bench. However, the first air test can be done with just about everything still on the vehicle. There are a few stickies to follow to help nail it down. You should have a very good idea of what is wrong with just the valve covers off, if needed.
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Old 04-15-2013, 09:31 AM
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Thanks for the Reply.

My truck is a 2005. I agree, the air test will be the next step. I just need to do some searching and see what I need to buy.
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Old 04-15-2013, 12:37 PM
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M12x1.5 to 3/8"NPT-F. Step up from that for your air connection. It is nice to have a shut off/on valve at the connection, but a quick release keeps the price down if you don't have the parts lying around.
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Old 04-16-2013, 04:53 AM
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Thank you sir!!!! Do you know the recomended air pressure?
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Old 04-16-2013, 06:16 AM
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100psi plus or minus works just fine.
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