May I jump in here with my friends cold start problem..
He spent 1600 dollars by an independent shop that threw new glow plugs, relay and two injectors.
the whole time was a warn out HPOP... very disappointing when a shop does not do a complete diagnosis and just throws parts at the problem
If I had my autoenginuity at the time that could have been eliminated.
For anyone that does not know already....KEEP THAT OIL CHANGED!!

 

Thanks for the suggestion, cord812. I hadn't really given much consideration to the HPOP, but will add it to my list of potential problem areas. My truck is a 99.5 with 230K and has never had any injector work that I know of. How common is an HPOP problem with that kind of mileage?

 

Got that oil changed yet? That's my bet (or at least the next step).
Good luck, you'll get it.

 

I had the same problem with my 01. I checked out all the things even put a diagnostic computer on to check out the HPOP pressure. All good. It turned out to be the fuel injectors. I replaced all the injectors with a set of rebuilt ones and it has made all the difference in the world. I got mine from Pensacola Fuel Injectors. They do a lot of them and so far I am very happy with the results. Their prices are competetive and they give you 30 days to return the old ones before they charge your credit card for the cores. If you buy one of their super kits, it comes with new glow plugs, valve cover gaskets and wiring harness as well as the injectors. You can order for them online, but they will want you to call them to reaffirm the year of your truck and confirm the credit card info for the cores and shipping addres. It is a bit of a bother, but I would rather them get it right the first time. They are also very open about answering questions.

If you do change the injectors, keep in mind, when you first start it, it will blow quitte a bit of white smoke and you will have to drive the truck about 50 miles to work the air out of the system.

Also, be sure and turn the engine over with the starter for about 30 seconds with the glow plugs out to purge the excess oil and fuel out of the cylinders to prevent hydraulic lock.

 

Thanks for the input Hawk180, how many miles did yours have on it?
I got the oil changed to 5w-40 rotella synthetic. It was 25 this morning and it started pretty easily, but did smoke a little and run slightly rough for a little bit after it started. Not really cold enough yet to give it a good test.
One thing I noticed was that the glow plug relay came on and stayed on for only about 25 seconds this morning. I expected it to stay on longer than that at 25 degrees. When I tested it with a voltmeter the other day it was in the 40's and it stayed on for a full minute or better. I didn't use a voltmeter at the relay today, but I can hear it click off from inside the cab. I usually wait till I hear it click off before I start it so that full battery power goes to the starter. Should I be concerned that the GPR only stayed on that long? If so, what components might be faulty to cause it to not stay on as long as it should?

 

At 25 degrees it should stay on the full 2 minutes. I would think it is bad if it don't.

Chet

 

Here's one more really SIMPLE potential solution....

Check your oil level.

I have a small oil leak on my truck and just had forgotten to check the level lately, and here's what I would get on cooler weather startups.

Start engine, let idle until GPR shuts off, leave driveway and mosey on up the road until the engine would sound like it was choking and would shudder, lose power, and potentially even shut down. Once the engine got warm, it would run great. BTW, I'm running 5w40 full syn and the oil is not old or yet needing to be changed.

Solution.... 2 gallons of oil!! The oil was barely showing on the dip stick when I finally checked it. What was happening was that even the low vis syn was running just low enough to start starving the LP oil pump while it was cool and being demanded while leaving the house. Once the oil got warmer and would flow more quickly, it would make it back to the sump fast enough to handle acceleration and highway speeds. While it was not warm, it just would not make it back down into the sump fast enough for the LP oil pump.

Ford did not do everything well, but their application of the oil pressure switch is a real winner and works very well!

 

If you haven't tried it already, unplug your ICP sensor in the am and see if it starts ok.
If there is oil in the socket it 's probably bad.

 

My truck has 251K on it. It was doing the same thing with the glow plugs and the wait to start light. I had already changed the GPR, so while I was changing the injectors, I put ib a new set of DieselRX glow plugs. The wait to start light stays on now for around 6-8 seconds. Then the truck starts right up. It surged a bit this morning at 19 degrees, so I am going to change over to full synthetic 5W-40. But even at that temp, it starts now with no problem.