A common problem of the 6.0L Power Stroke is hard hot-start issues caused by leakage in the engine's high-pressure oil system, which operates the fuel injectors. Possible leakage locations include the high-pressure oil pump, IPR valve, STC fitting, branch tubes, standpipes, dummy plugs, oil rail ball tube o-rings, injector inlet seals, and others. If the problem prevents the system from attaining the 520 PSI required, the truck will not start under any condition—hot or cold. Locating the exact source of the leak(s) is the challenge.
The Traditional Method
Most technicians locate the source of the high-pressure oil leak by connecting shop air to the high-pressure oil system through a proxy ICP sensor adapter. This method has several problems associated with it. First, the IPR valve is normally open and must be closed by a scan tool or a standalone IPR driver tool or air pressure will not build in the system. Second, IPR valves are not designed to seal completely, and they will always leak some air during the testing process. Unfortunately, the sound of one air leak will make it difficult or impossible to locate other leakage points—especially small leaks toward the rear of the engine. Finally, standpipes have an internal check valve that prevents reverse flow, rendering the conventional test method useless.
The IPR Solution
The IPR Air Test Tool replaces the IPR valve so that the system can be completely sealed and even the smallest leaks can be detected. No scan tool or IPR driver tool is required, lowering tool investment. Leaks of any size can be detected because the IPR valve is removed from the system, and it is possible to pressurize a system with shop air, close the shutoff valve on the tool, and leave the system pressurized overnight. Further, engine builders can quickly verify that an engine has no high-pressure oil leaks before reinstalling the engine. The IPR Air Test Tool allows systems with the latest, updated standpipes to be tested.
IPR Air Test tools are built to last a lifetime with professional grade components. They are constructed in the USA, and the heavy duty Eaton hydraulic hose is rated up to 5,300 psi. Each tool includes three extra o-ring sets for the IPR fitting.
Two purchase configurations available as either a complete tool with IPR replacement fittings, heavy duty hose, and shutoff valve assembled, or the IPR replacement fitting only. In the Complete IPR Air Test Tool option, the ability to 'air-up' the system and trap the air pressure by closing the shutoff valve allows even the smallest leaks to be detected. The absence of any unwanted air noises from leaking air lines connected with quick connect couplings makes locating the real problem easier. The IPR replacement fitting only cost-saving option is intended for lower volume users, such as individual truck owners. At less than the cost of one hour of diagnostic time in most areas, this tool can save your hundreds or even thousands of dollars.
The complete system can be tested in less than 20 minutes: to connect, just remove the air cleaner, FICM, and coolant degas bottle—turbo removal is NOT required; remove the IPR valve and thread in the tool, hand tightening using the hose; connect shop air and listen for leaks. To locate the smallest leaks close the shutoff valve on the tool to seal the system. If desired, a scan tool can be used to monitor air pressure in the system by observing the ICP sensor reading. To prevent costly comebacks, we recommend air checking every 6.0L for high-pressure oil leaks after any part of the system has been disassembled.
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