That would mean that the other ipr wasn't bad then it was stuck too so what are the chances of that because it was doing the same thing with the old ipr?

 

You would probably be the first. Do you still have the old ipr?

 

Yes I do and the orings were fine and it didn't look bad judging solely on appearance. That's why the mechanic is leaning towards the hpop because of it reacting the same to both ipr valves and starting up and running unplugged he figured a malfunction internally could be the only reasonable explanation. He said that's the first time he's seen one start unplugged

 

You test the HPOP by measuring Duty Cycles of the IPR.

the truck is starting with the IPR Unplugged, so there is not a thing wrong with the HPOP, it can make more than enough pressure.

I'd be sure to check where it came from.
There is a website claiming they are rebuilding them, and... its nto a rebuildable part.


Not many people know a lot about the motors in these trucks, thats generally why mechanics say they suck or bad mouth them.

 

Were here to help man.

Stick with us. We'll try and help you figure this out.

Where you located at?
might be somebody near by who can jet over and help you take a look.

 

I'm in Washington pa and the ipr isn't rebuilt it's a new one

 

Alright that's good to know on it being new for sure.

You can pull them apart and clean them.

I cannot think of any good reasons to help you at the moment.
We will have to wait on somebody else.
But the HPOP's in these trucks don't really go bad unless you run dirt though them.

 

You might find this article particularly interesting. HEUI - How High-Pressure Oil Injection Systems Work - Diesel Power Magazine
I'm not sure how familiar you are with the HEUI system, but if you aren't you should be. This knowledge will help you troubleshoot rather than throw parts at it.


I've been rolling it around in the back of my head for a while, and I can't think of how your engine would be able to build enough pressure to run, let alone max pressure, with the IPR unplugged unless its stuck.

 

Let's say it isn't stuck....what would be the next logical explanation?

 

On a 96 the edge filter was moved internal to the HPOP where earlier models it was a part of the IPR. If the edge filter becomes clogged then the IPR will have no effect since high pressure oil can't drain past it. This can occur if covers, such as the oil pan were replaced / resealed using the Ford goop and to much was applied, contaminating the oil.

If indeed the edge filter is clogged then replacing the HPOP is the only solution. I have a link somewhere describing this ...

 

Here is the link ... Technician_HPOP_Guide.pdf

 

That's curious. If it were mine and I determined the filter was blocked, I think i'd try back-flushing it with brake cleaner before I decided to just replace the thing.

 

OR, take out the "Non-serviceable plug", gain access to the edge filter for cleaning, and then replace the "Non-serviceable plug" per the instructions on dieselorings.com

http://www.dieselorings.com/docs/service_plug.pdf

Riff-raff and dieselorings.com both sell this kit. I have used it to repair a bad HPO leak at the "non-serviceable plug". Worked great.

 

I took the hpop off flushed it all out with cleaner and took our the edge filter and flushed then put back together and truck still is the same and starts and runs with ipr unplugged. I took a voltage check on the wires going to the ipr with key on and when it was running and both showed a steady 12 volts is this normal? I thought it was supposed to be less....could this have burnt up my new ipr and what would cause that?

 

I can't remember which wire is which, but one wire is 12V with the key on. The pcm grounds the other wire to complete the circuit in a pulsing fashion. The amount of time grounded is determined by the pcm and is called duty cycle, shortened to DC%.