Replaced HPOP ICP IPR, 200km later dead
 

Hey guys, did a side job for a customer, ICP blew open, figured it over worked the HPOP, customer wanted me to treat it like it was my toy I was fixing, so I did the egr delete , SS HPOP screen, all o rings and gaskets, IPR, 07 oil cooler kit. Filters oil change. Truck ran great after had some sort of hydro lock on enishal start up after the work was preformed, rotated engine backwards to clear it out. Stated up great IPR was at 21% and had proper ICP pressure, ran it hard and was happy, returned to customer. Next day he's showing off new found power, and it had a miss, lost power and slowly died as it got. Ack to a buddy's place. I have 16psi ICP. Hoping for a back rail stc fitting, any ideas? Oil is clean aside it looking like oil from fresh rebuilt motor, in other words very very small amounts of metallic. Any good ideas?

What year truck is this? How does an ICP blow open?

Probably needs a new IPR or at least a cleaning and new screen/o-ring. This is quite common on trucks that just had the HPOP replaced.

ICP blew a hold through the pigtail. Common. IPR and HPOP screen was replaced, it is a 2003 sorry

Same exact thing happened to my 03 after doing studs, hpop oil cooler, egr delete.
new IPR . no start code P2623. pulled IPR, inspected and replaced the screen (no hole in the screen just junk). Fired right up.
Second time no start. code P2623. Pulled IPR to inspect. This time blew hole in screen. had to replace IPR. (no point in hoping debris didn't get inside IPR).
wouldn't start. Still code P2623. Pulled it 2 more times with no starts. Then realized the new IPR was bad out of the box. had to pull teeth with the stealership to get an exchange. But did.
Installed it fired right up. No more P2623!
It doesn't take much junk on the screen to keep the IPR on the open circuit position. And if the screen is even a little ruptured the IPR needs to be replaced.
You can check for wire chafing also.

Oil usually leaks down from the top of the motor to the ICP pigtail, never heard of it blowing through the sensor... I'd assume that would shut the truck right down. Regardless, this is why the sensor was moved for 05+ trucks.

Typically, even if you put a new IPR in already, they need another sometimes after HPOP replacement, I've seen it more than once. I would at least start with pulling the IPR, you might find the screen destroyed on it again like 1964horseman is saying.

well, IPR is stuck wide open. you guys called it, i gotta flush this thing out now some how and the best way would be appriciated. the ss screen was intack and had a fair amount of debris in it aswell. HPOP i could still feel and hear what i would assume is vanes moving and it sucks and blows nicely on the bench, someone could easly make a bench tester if they had some old parts. i think i should make one myself... just need a 5000 psi gauge.

Also with this being a 2003 it has the circle intake not the horse shoe style so the IPR is NOT accessible with the intake on.

Let us know what you come up with for fixing the IPR, because most guys from what I see just end up buying a new one... I've never had to do it myself, but I'd imagine there's a way to clean it up.

I have to pull the intake to replace, I'm putting in a new one for 150$ from ford. Gona flush this thing with solvent and 40l of oil. I don't understand how this much metal could get past the first filter though, bypass valve?

It's really common right after an HPOP replacement for whatever reason, you're not alone on this.

I agree, for the work that has to be done to get back there, might as well toss a new one in.

well i'm gonna order a new screen, put it on the now bad one to ford, because 311$ is theift! i can get them for 150 in the USA. anyways, flushed the oil once i got it running and went up and down the block. still had alot of metal in it, but i felt it was good enough to only do one oil change (2 since HPOP) i also cleaned out the SS hpop screen, blew out the oil cooler, and rinsed out the HPOP.

FYI supplying air to the top of the HPOP will cause the seal to push out on the main shaft, or leak past it.


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