Matt Saunoras Posted September 8, 2012 Share Posted September 8, 2012 Got an 125k 05 no-start that I verified has base pressure but only builds 100-200 psi ICP. I'll be honest I can't air check it because it's not at work. SYNC is good, FICM voltage good, no codes, IPR being commanded to 85% I was going in after the STC (customer request) and found the IPR seal on the end was pushed out of place and the screen was popped out of position and oval shaped. The screen was not blown through at all though. I've never seen this or even heard of it. Could this be the source of a big enough leak for a no start? Should I just reseal the IPR on my way back together? I didn't expect to find the STC fully blown because it still built some ICP and as I suspected it was very loose and not seperated. The IPR seal threw me off a little bit though. Quote Link to comment Share on other sites More sharing options...
Alex Bruene Posted September 8, 2012 Share Posted September 8, 2012 I've seen countless mangled IPR seals. I have yet to have a seal cause a no-start. I assume you would have removed the IPR after removal of the turbo-seeing that you are going after the STC. If you've gone that far, I'd continue removing the pump. I'm not saying that I don't think the IPR could be the issue... I just don't think the IPR seals are the issue. Quote Link to comment Share on other sites More sharing options...
Matt Saunoras Posted September 8, 2012 Author Share Posted September 8, 2012 Thanks, that's what I thought. From what I heard the truck was getting harder and harder to start eventually leading to a no-start all the time. I am going to borrow a small portable air compressor to pressurize the branch tube opening before I go back together. The pump is out as we speak Quote Link to comment Share on other sites More sharing options...
Keith Browning Posted September 8, 2012 Share Posted September 8, 2012 right... but an IPR seal blown out means that the screen has been pushed off of the IRP with the screen broken or in-tact. I have seen crap stuck in the IPR allowed by the screen being pushed into the pump bore. Regardless of that, the screen keeps the o-ring and the backer seal in place. The IPR does not necessarily need to be replaced as a seal and screen kit is available (3C3Z-9H529-A) just be sure there are no seals or the screen left in the HPOP. Clean the IPR out with Brakleen and inspect with a good light (and good eyes) if there is debris caught you can see it. Quote Link to comment Share on other sites More sharing options...
Matt Saunoras Posted September 8, 2012 Author Share Posted September 8, 2012 Thanks Keith. Hopefully I'll get a chance to throw this thing back together tonight. I'll put it back together with a new pump fitting and the old IPR (resealed) and let you know what fixes it. Quote Link to comment Share on other sites More sharing options...
Matt Saunoras Posted September 9, 2012 Author Share Posted September 9, 2012 One of the two repairs fixed it. I resealed the IPR and put in a one-piece HPOP connector. Also installed a new oil cooler and fuel pressure regulator kit at customer request. I air checked it at the branch tube and it was sealed up tight. No audible noise at either bank. The pump fitting wasn't totally seperated but it was the loosest one I've ever seen. I've actually never seen a cold no start caused by the pump fitting if it wasn't totally seperated. I'm satisfied, thanks for the input guys. Quote Link to comment Share on other sites More sharing options...
Keith Browning Posted September 9, 2012 Share Posted September 9, 2012 Excellent! I would bet the fitting was your problem. but there have been times where I found multiple issues and wasn't sure what exactly fixed the concern. Quote Link to comment Share on other sites More sharing options...
cbriggs Posted September 26, 2012 Share Posted September 26, 2012 I have seen and repaired at least 5 or 6 no-starts caused by a bad oring on the end of the ipr. On the other hand I have seen and repaired hundreds of no starts caused by an stc fitting failure. Quote Link to comment Share on other sites More sharing options...
Matt Saunoras Posted March 30, 2013 Author Share Posted March 30, 2013 Alright, digging this one back out. Getting more and more accustomed to 6.0 diag and have run across a few different concerns caused by IPRs Most of what I'm finding is dirt coming from the high pressure oil reservoir finding its way into the IPR. Never had one of my cooler jobs come back though so I think it's an avoidable situation. This is one from this week. P2290 in memory, noticable rough idle and rough running, feels like a misfire but not flagging an individual cylinder. Truck starts fine hot or cold. Gave it a couple hard throttle snaps to see if I could dislodge the STC with no avail. Noticed IPR ramped up to 85% while the truck was idling but ICP stayed normal. Someone pretty recently put coolers on this truck, surely dirt in the reservoir. This one was a no start, no ICP. Air check proved pretty quickly that the IPR was sticking. This is another truck with an unknown history Another no start towed in but oddly enough started fine the next day. Went in looking for the STC again and found the screen blown in and seal torn. Quote Link to comment Share on other sites More sharing options...
Keith Browning Posted March 30, 2013 Share Posted March 30, 2013 I have come to the conclusion that debris is the only thing that causes these types of failures with the IPR screen. Even the ones that come off the tip of the IPR. I think the added pressure caused by the clogged screen causes high pressure oil to get behind the o-rings and push the screen off. Nice examples Matt. Quote Link to comment Share on other sites More sharing options...
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