I need some help with my 96PSD. It up and died on me last summer while going down the road. I found right away fuse 22 was blown, but I didn't have a spare. Called for someone to drag me home. Once there I unhooked the fuelbowl heater and put in a new fuse. Well it blew immediately and a wisp of electrical smoke came up from the left front of the fuel bowl. Not right up by the bowl but from somewhere around in there. I wanted a better look at it so I got right up where I could see and put in another fuse. This time it didn't blow but now the engine won't start.

I do hear the injectors clicking, the glow plugs cycle on and off, and the tach shows when the engine is cranking. No smoke when cranking so apparently no fuel is being injected.

What could be the problem? I did make sure the HPOP reservoir was full. Would a HPOP gone bad cause a wire to smoke?

 

Take a good look at the ipr wiring. It's on the backside of the hpop and if its bad, there will be no smoke, and it won't start.

 

Agreed ^^

If the IPR wiring is melted or shorted, it could have been the source of the wisp of smoke you saw since the wiring goes down in the front of the fuel bowl to the IRP. The IPR is actually kind of buried down in there, but the wiring is part of the fuel bowl harness, and I've seen more than one IPR harness that was melted from a fuel leak that ate the wire insulation.

 

Thanks guys. Looks like I have a starting point. I read up on HPOP operation and it makes sense.

I did remove a high pressure line and cranked the engine over. I thought the flow was rather small and weak. If I read right, the IPR dumps oil to sump if it receives no power or ground signal. Is this correct?

 

These ain't no old mechanical injectors.let's leave the whole line cracking to the idi boys lol

 

The only thing cracked here is the guy that started this thread LOL

 

Lol I sure feel you....
I spent my evening under the hood..fun

 

Make sure the fuel bowl heater wire is taped up and wont rub on any thing. Do you have a wts light? Aaron i hope you had a tape measure while you were under there. Haha.

 

No tape measure.

 

WTS light, yes and the glow plugs cycle like normal. I put and led light on the dash, so I know when the gp's are on.

Bowl heater isn't taped but it is hanging in mid air not grounded while I'm testing. But you made me think I should test it for power.

 

I got in there and looked over the wiring real good and the only trouble I can identify is the plug in for the ipr. The insulation at the connector looks cracked up and And it makes the only sense for the wiring smoke I saw. Now I need to find a new connector for it.

Using a test light it gets power when connected.

I tested the wire for the bowl heater and it isn't getting power. Does it run all the time or only below a certain temp?

 

RIFFRAFF FORD DIESEL PERFORMANCE PARTS


You can get an ipr pigtail from Clay ^^, or you could check ford, but they will probably have to order it too.

 

You will have constant power to the plug that goes to the fuel bowl heater.

 

I found a pigtail and ordered a new ipr while I was at it. Just in case.

 

My local IH dealer had in stock..2miles from my house :-)