97 Powerstroke PCM issue and Fuel Pressure help needed.

[GRN250]

After getting a friend's truck running, I have been putting some miles on it to verify it is ready to be returned. The truck was running great and a check engine light illuminated; the truck immediately lost power. The key was cycled and the power returned again only to have the same issue within a 1/4 mile. After limping the truck home, I connected AutoEngunity to it and zero DTCs were able to be retrieved. The PCM has been refurbished previously so it was removed and sent for inspection. It returned with no problems found and once installed, the same issue returned during a test drive.

The CPS and ICP are new Ford items purchased from a dealer (not ebay or amazon). The hpop is maintaining 600-700psi. The fuel pump was previously replaced but I don't have a pressure value to provide. I have searched the forum for similar issue but didn't locate an exact match. Your help is greatly appreicated.

POST #8 has fuel pressure issue details.

 

[Mark Kovalsky]

See if the PCM pin for Keep Alive Power has +12v at all times, key off, too.

 

[GRN250]

See if the PCM pin for Keep Alive Power has +12v at all times, key off, too.

The keep alive power has 12v at all times. Do the OBS trucks have the same OBD II protocol as the "newer" 7.3 trucks? I assumed it would be the same when connecting AE to it to pull the DTCs. Thank you.

 

[DEEZUZ]

On Obs I use what's called a Mastertech.

Is your obd port v1 or v2?

If it's v1, thw square port, nothing works as good as the MasterTech

 

[Patrick Feeley]

94.5 are the only ones with an OBD1 port (in the engine bay on driver's firewall). They also have the OBD2 port under the dash which was originally inactive (but many times activated by dealers when in for service). 95 through 97 have only the OBD2 port under the dash. Cheers!

 

[DEEZUZ]

I feel I've had some Obs with the square port under glove box. Mainly bc you then also have to feed my scanner 12v then with alligator clamps.

 

[GRN250]

This 97 has an OBD II port by the glovebox. The AE software is able to perform special functions and trend live data but does not retrieve the DTC causing the power loss. The check engine light illuminates when the loss of power occurs so I expect to find the corresponding TDC. Thank you.

 

[GRN250]

PCM was sent in for more testing and after being returned, I have been able to pull the P1211 code from it.

The fuel pressure was checked at 28psi and I haven't been able to get it above 34psi. These values appear to be on the low end of acceptable. Prior to my starting on troubleshooting, the truck had the fuel pump, ICP sensor, hpop and IPR replaced. Stated this in the first post when troubleshooting the PCM

With the truck at idle and engine temp at 190F, the ICP is at 590-600psi with the IPR at 29%. Reading through several posts and forums, I was expecting an IPR value closer to 10-15% with the same ICP pressure. With KOEO, the IPR reads 14.8% and ICP 0psi. Does the engine need to be warmer to expect the lower IPR duty cycle?
- The injectors have passed a buzz test and are passing the same amount of oil, through the spout, while running. No injectors appeared to be leaking oil around their base.
-The fuel pressure regulator was rebuilt with no improvement so a new OEM fuel bowl assembly was installed to eliminate wear concerns on the FPR housing. This made no improvement. The fuel in the bowl appears clean but the filter was replaced.
-Fuel has been siphoned from a clean container to eliminate a possible fuel supply restriction. Fuel pressure didn't change.
-To isolate a possible leak, Pressure Leakage Adapter Set D94T-6600-A is required. Is there a supplier for this kit other than Ford?

I have read several posts where the IPR could cause fuel pressure issues when accompanied with lower ICP readings. The ICP readings appear normal. I am trying to locate a kit to test for leaks but haven't found one yet. Appreciate any help you can provide. Thank you.