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Home >> Ford >> 2003 >> Excursion 6.0 P, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (ENGINE CONTROLS - SELF-DIAGNOSTICS - 7.3L (995, 996 F650/750, 99F E Series & 99F F450/550) DIESEL) >> System Tests >> Test KE: Injection Pressure Regulator >> Testing

Test KE: Injection Pressure Regulator: Testing

WARNING: This page is about a different variant/trim than selected.
FAULT CODE SETTING CONDITION

Fault Code KOEO KOER Continuous Memory
P1209
All except F650-750 (1)     Test KE  , Step  15)
F650-750     Test KE  , Step  15)
P1211
All except F650-750 (1)(2) Test KE  , Step  15) Test KE  , Step  7) Test KE  , Step  15)
F650-750 (2) Test KE  , Step  15) Test KE  , Step  7) Test KE  , Step  15)
P1282
All except F650-750 (1)(2)   Test KE  , Step  5) Test KE  , Step  5)
F650-750 (2)   Test KE  , Step  5) Test KE  , Step  5)
P1283 Test KE  , Step  1)    
(1) MIL illuminates when fault is detected in second drive cycle (California, OBD-II calibration).

(2) MIL illuminates when fault is present (Federal).
    NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  1. 1) KOEO DTC P1283: Check Power Feed Circuit
    DTC P1283 indicates high or low resistance in IPR circuit. Possible causes are:
    • Mechanically Stuck IPR
    • IPR Circuit Open, Or Shorted To Ground Or Power
    • Loose Or Poor Harness Connection
    • Faulty IPR

    Turn ignition off. Disconnect IPR connector. IPR is mounted on high pressure oil pump, located on top of engine. On Econoline and F650-750, remove PCM PWR relay from battery junction box. Battery junction box is located on left front of engine compartment. On Excursion and F250-550, remove PCM PWR relay from central junction box. Central junction box is located behind lower left side of instrument panel. On all models, measure resistance of Red wire between IPR harness connector and PCM PWR relay cavity No. 87. See Figure or Figure . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, check for open in IPR PWR circuit. On Excursion and F250-550, check fuse No. 22 (20-amp) located in central junction box. If fuse is okay, check for open in IPR PWR circuit (Red wire) between IPR and battery junction box (Econoline and F650-750), or central junction box (Excursion and F250-550). Repair circuit as necessary. See WIRING DIAGRAMS . Clear DTCs and retest.

  2. 2) Check IPR Coil Resistance

    Using DVOM, measure resistance between IPR terminals. If resistance is 5-20 ohms, go to next step. If resistance is not 5-20 ohms, replace IPR. Clear DTCs and retest.

  3. 3) Check IPR Control Circuit For Short To Ground Or Voltage

    Turn ignition off. Disconnect PCM connector and inspect for damaged pins, corrosion and loose wires. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between test pin No. 83 and test pins No. 25, 51, 71, 76 (Econoline), 77, 97 and 103 at breakout box. If all resistances are more than 10 k/ohms, go to next step. If any resistance is 10 k/ohms or less, locate and repair short to ground or short to voltage in IPR control circuit (Yellow/Red wire between PCM and IPR. Clear DTCs and retest.

  4. 4) Check IPR Control Circuit Resistance

    Using DVOM, measure resistance of Yellow/Red wire between test pin No. 83 at breakout box and IPR harness connector. See Figure or Figure . If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in Red/Yellow wire. Clear DTCs and retest.
    5. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  5. 5) KOER & Continuous Memory DTC P1282: Attempt To Start Engine
    DTC P1282 indicates injection control pressure was more than 3675 psi for 1.5 seconds (possible grounded IPR control circuit). If electronic concern with IPR or ICP is not found, see TEST 10A: INJECTION CONTROL PRESSURE TEST (OIL AERATION/POOR IDLE) under ENGINE PERFORMANCE DIAGNOSIS in SYSTEM & COMPONENT TESTING - 7.3L DIESEL. Possible causes are:
    • Intermittent Short To Ground In IPR Control Circuit
    • Mechanically Stuck IPR

    Turn ignition off. Disconnect IPR connector. IPR is mounted on high pressure oil pump, located on top of engine. Attempt to start engine. If engine does not start, go to next step. If engine starts, replace IPR. Clear DTCs and retest.

  6. 6) Check For Intermittent Short To Ground

    Disconnect PCM connector and inspect for damaged pins, corrosion and loose wires. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between chassis ground and test pin No. 83 at breakout box. Resistance should be more than 10 k/ohms. Wiggle and bend small sections of wiring harness starting at IPR connector and working toward PCM. A fault is indicated when resistance changes to 10 k/ohms or less. If fault is indicated, isolate intermittent short to ground and repair as necessary. Clear DTCs and retest. If no fault is indicated, clear DTCs and repeat KOER ON-DEMAND SELF-TEST  under QUICK TEST. If DTC resets, replace PCM. Clear DTCs and retest.
    7. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  7. 7) KOER DTC P1211: Check Engine Oil Quality & Viscosity, & Fuel Grade
    DTC P1211 indicates that injection control pressure was more than or less than commanded desired pressure during self-test. Possible causes are:
    • Incorrect Oil Or Viscosity
    • Poor Oil Quality
    • Gel Fuel Or No Fuel
    • Low Fuel Pressure
    • Faulty IPR Valve
    • High Pressure Oil System Leak
    • Faulty High Pressure Oil Pump
    • Faulty PCM

    Verify correct oil quality, viscosity and fuel grade are being used for temperature conditions. Replace oil or fuel as necessary. Clear DTCs and retest. Ensure DTC does not reset. If oil and fuel are okay, go to next step.

  8. 8) Check Fuel Pressure

    Measure fuel pressure at regulator block. Measure fuel pressure with engine idling and while driving vehicle at Wide Open Throttle (WOT) with a full load. Fuel pressure should be 45 psi (310 kPa) at idle and 45-80 psi (310-552 kPa) while driving vehicle at WOT with a full load. If fuel pressure is as specified, go to next step. If fuel pressure is not as specified, repair fuel system as necessary. Clear DTCs and retest.

  9. 9) Check Oil Reservoir Level

    Remove plug in top of oil reservoir and check level. If oil level is within 1" (25.4 mm) of top of reservoir, go to next step. If oil level is not within 1" (25.4 mm) of top of reservoir, check and repair cause of low fluid. Top off fluid. Clear DTCs and retest.

  10. 10) ICP Sensor Check

    Using scan tool, access ICP PID from PID/DATA MONITOR & RECORD menu. Turn ignition on. If ICP PID reading indicates zero psi, go to next step. If ICP PID reading does not indicate zero psi, replace ICP sensor. Clear DTCs and retest.

  11. 11) Oil Aeration Check

    Using scan tool, access ICP PID from PID/DATA MONITOR & RECORD menu. Start engine. Raise engine speed to Wide Open Throttle (WOT) for 3 minutes. If ICP PID reading increases to more than 1800 psi, change engine oil and repeat test. Clear DTCs and retest. If ICP PID reading does not increase to more than 1800 psi, go to next step.
    12. NOTE: During KOER ON-DEMAND SELF-TEST, ICP will be commanded high to 2466 psi (17 MPa). Then commanded low to 725 psi (5 MPa), and then EBP will be commanded high and low.

  12. 12) Check ICP Sensor
    Disconnect ICP sensor connector. Sensor is located on top of engine near rear of generator. Install ICP/EBP Adapter Cable (D94T-50-A) between ICP sensor and sensor harness connector. Start engine. Using DVOM, measure voltage between ICP signal circuit and ground at ICP/EBP adapter cable. See Figure. Perform KOER ON-DEMAND SELF-TEST  under QUICK TEST. If voltage increases to more than 3 volts and then decreases to about one volt during ICP portion of KOER self-test, replace PCM. Clear DTCs and retest. If voltage does not increase to more than 3 volts and then decrease to about one volt during ICP portion of KOER self-test, go to next step.

  13. 13) Injector Leak Check

    Disconnect high pressure hose from right cylinder head. Using Oil High Pressure Leakage Adapter Set (D94T-6600-A), plug right high pressure hose. Using scan tool, access and monitor IPR PID from PID/DATA MONITOR & RECORD menu. Start engine and record IPR PID reading. Turn ignition off. Reconnect right cylinder head high pressure hose. Disconnect high pressure hose from left cylinder head. Using oil high pressure leakage adapter set, install onto left high pressure hose. Again, monitor IPR PID reading. Start engine and record IPR PID reading. If IPR PID readings are not within 2 percent of each other, repair internal oil leak on cylinder head with the higher IPR PID reading. Clear DTCs and retest. If both IPR PID readings are within 2 percent of each other, replace IPR. Clear DTCs and retest. If DTC P1211 is still present, go to next step.

  14. 14) Oil System Pressure Test

    Check for pressurized oil leaks. See TEST 10A: INJECTION CONTROL PRESSURE TEST (OIL AERATION/POOR IDLE) under ENGINE PERFORMANCE DIAGNOSIS in SYSTEM & COMPONENT TESTING - 7.3L DIESEL. Repair as necessary. Clear DTCs and retest. If no leaks are found, replace high pressure oil pump. Clear DTCs and retest.
    15. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  15. 15) KOEO & Continuous Memory DTC P1209 Or P1211:
    DTC P1209 indicates injector control pressure system fault. If DTC P1211 is set during normal engine operation, it indicates engine is operating in open loop control and injection control pressure is more than or less than desired pressure. If DTC P1211 is set during KOER ON-DEMAND SELF-TEST, it indicates ICP system failed step test and could not maintain commanded pressure. Possible causes are:
    • Incorrect Oil Or Viscosity
    • Poor Oil Quality
    • Gel Fuel Or No Fuel
    • Low Fuel Pressure
    • Faulty IPR Valve
    • High Pressure Oil System Leak
    • Faulty High Pressure Oil Pump
    • Faulty PCM

    Verify correct oil quality, viscosity and fuel grade are being used for temperature conditions. Replace oil or fuel as necessary. Clear DTCs and retest. If oil and fuel are okay, go to next step.

  16. 16) Check Fuel Pressure

    Measure fuel pressure at regulator block. Measure fuel pressure with engine idling and while driving vehicle at Wide Open Throttle (WOT) with a full load. Fuel pressure should be 45 psi (310 kPa) at idle and 45-80 psi (310-552 kPa) while driving vehicle at WOT with a full load. If fuel pressure is as specified, go to next step. If fuel pressure is not as specified, repair fuel system as necessary. Clear DTCs and retest.

  17. 17) Perform KOER On-Demand Self-Test

    Perform KOER ON-DEMAND SELF-TEST  under QUICK TEST. If DTC P1211 is present, go to step  9). If DTC P1211 is not present, go to next step.

  18. 18) Check Oil Reservoir Level

    Remove plug in top of oil reservoir and check level. If oil level is within 1" (25.4 mm) of top of reservoir, go to next step. If oil level is not within 1" (25.4 mm) of top of reservoir, check and repair cause of low fluid. Top off fluid. Clear DTCs and retest.

  19. 19) ICP Sensor Check

    Turn ignition on. Using scan tool, access ICP PID from PID/DATA MONITOR & RECORD menu. If ICP PID reading indicates zero psi, go to next step. If ICP PID reading does not indicate zero psi, replace ICP sensor. Clear DTCs and retest.

  20. 20) Oil Aeration Check

    Using scan tool, access ICP PID from PID/DATA MONITOR & RECORD menu. Start engine. Raise engine speed to 3300 RPM for 3 minutes. If ICP PID reading increases to more than 1800 psi, change engine oil and repeat test. Clear DTCs and retest. If ICP PID reading does not increase to more than 1800 psi, go to next step.

  21. 21) Check IPR Duty Cycle Under Load

    Using scan tool, access IPR PID from PID/DATA MONITOR & RECORD menu. Road test vehicle with engine at Wide Open Throttle (WOT) and with full load condition. If IPR PID value increases to 65 percent, replace IPR valve. Clear DTCs and retest. If IPR PID value does not increase to 65 percent, no concern is indicated at this time. Clear DTCs and retest.
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