I didnt see EGR Delete, have you pulled the EGR and cleaned it up? what is the valve vp and dc? also the Aggressive tune did you return back to stock and see if things get better?

 

EGR delete is one of the things on the to do list. I've been running my truck with the EGR valve unplugged in the closed position since '05.
I haven't returned the tune to stock. What I really liked the most from "Agg Street" tune was better fuel efficiency. But I'd rather have my truck actually running stock than not at all.

 

I've already said it once in this thread, but I'll repeat it in case you overlooked it - your symptoms (and the OP's) mirrored mine when the HPOP died. Since you have an '04 (and the OP has an '03) you both have the early style HPOP, as I do. I pulled out what remaining hair I had left until I replaced the HPOP. Since then it's run perfectly.

 

Yeah, I saw that. And I was afraid that may be the case with my truck. I was wondering if fireballer discovered the HPOP to be his truck's problem too. I figured if a few guys have similar symptoms and discover it's the hpop, then that's probably where I need to be looking.

I initially thought it might be gelled fuel. Mine died right after we had some freezing weather and I'd forgotten my PS anti gelling additive on the previous fill-up. But even after replacing both fuel filters and finding no evidence of gelling and then having warm days, I couldn't get it to start.
It makes sense that if the hpop has finally reach a failure point then there wouldn't be adequate pressure to actuate the injectors, and therefore a "bogging down" upon acceleration attempts.

 

Too bad so many people never post back in the original thread - even after quite a few helpful posts are made!

That being said - the OP started another thread a couple of days ago where he is replacing the HPOP.

https://www.ford-trucks.com/forums/1...-question.html

 

Mark, I sure hope that the OP is not just throwing parts at it.


Sean

 

Yeah. Dead end threads are frustrating, especially when they're on to something that others may learn from. Well, Mark, thanks to you, others may find some continuity to the ideas started here. And as Yahiko points out, this thread may need yet another link to another thread if it turns out OP is throwing parts on the craps table.

PS
This reminds me, I should probably go back and make sure I've completed the ideas started on any of my old threads.

 

Your right.

Threads are like any project.
You need to finish what you start.


Sean

 

Well, OP must have a lot on his plate. I'll pick up and run with this a little.
I don't have the time or facilities to do extensive work on my truck at home. I agreed to the terms of my HOA and I'll do my best to honor them. Plus it'd take me a lot longer than a pro. So I put out some feelers and finally found a guy that seems like a good honest diesel tech in my area. He's the lead tech at a local Ford dealership and will do some weekend work on the side for me. I had to have my truck towed to him. He has diagnosed the problem to be my HPOP gone bad. He said he turned off the injectors on one side and was able to get the engine to start. My weak HPOP couldn't actuate all the injectors, but could just get by to open half of them and run a little. Black1, it looks like you nailed it, thanks for the heads up.

I am eager to get my truck running again and was hoping to get the work done this weekend, but that obviously ain't happening at this point. I want to make sure I make the most of this project. A good chunk of my cost is going to be the work involved in just getting to the HPOP and putting the stuff back together, so while he's in there I want to take care of some other stuff. He also suggested Dummy Plugs, EGR Delete, check out the Oil Cooler and turbo. I confirmed I definitely need a new oil cooler and intend to go Ford with that. What he can do on the side will be limited to stuff that can readily be done with the cab on, so this won't go as deep as studding the heads. I told him that I'd like to do a little research before putting another stock HPOP in. So we're postponing till I figure this out.

Seemingly credible resources I've read indicate that the stock '03-'04 HPOP is an inadequate design/manufacture for it's purpose. I want a good reliable HPOP to replace my bad one. Is this Dieselsite 2003-2004.5 Heavy Duty High Volume 6.0L Billet High Pressure Oil Pump (HPOP) the one that has been proven most reliable in a '03-'04? Or is there a better option?

I could certainly use some advice on the other stuff to do while in there, but I'll start with figuring out the right HPOP to get.

 

I went with the Dieselsite HPOP. 15K on it so far and zero problems. No regrets whatsoever with that decision. It's a well-made piece.

 

Well, as you can imagine, my diesel guy is in demand. And having my non-running truck sitting around was making things very awkward for him. So I had to make a decision that following week to just get the thing running.

Furthermore I was really not sure if I was needing the old style HPOP or the newer style. I was still confused with the early '04 / late '04 vagueness. The '04 seems a bit of a transition version of the 6.0. I'm thinking about starting a thread just for the purpose of clearly defining the different versions of the 6.0 that Ford put out.

Anyway, we reached a point where the work needed to be done that Saturday(8/16) and I was out of time for ordering special stuff. And with respect for his time/experience/knowledge I just went with his recommendation on the right parts, with the exception of Ford Gold. I told him I'm done with Ford Gold and sticking with Cat1 ELC. I brought the RCD EGR Delete Kit, ELC coolant, and a new NAPA 4070 coolant filter. I bought the parts he compiled from the Ford parts department at the dealership where he works.

I took the wife's little suv down to pay for the parts a little before noon and he had a pile of my stuff laying next to the truck and was about to remove the turbo. Then I could clearly see the cast iron HPOP cover in the back valley of my engine (as opposed to the aluminum shroud that seals around the head of the new style HPOP). He said my truck and engine are really clean and appear to be maintained well.

Ideally I wanted everything fixed or upgraded that one can do when in that deep, but the reality was that we just needed to get it running and go from there. Here's what was done:

New HPOP 4C3Z-9A543-AARM
New Oil Cooler
Updated Dummy Plugs
New Gaskets/Hdwr: Intake manifold, HPOP Cover, Oil Cooler, EGR
Fluids: New oil/filter, coolant/filter
River City Diesel EGR Delete Kit

He finished about 8 that evening. He showed me the old HPOP where the seal blew out at the gear shaft. My original Dummy Plug O-rings looked fine, but he replaced as a precaution. I knew I was overdue for a new Oil Cooler, my EOT-ECT averaged 14° on the 20min drive home at ~75mph.

 

Glad your up and running. Mine has been down for almost 3 months while i found parts and time to work on it. I have the luxury of a big enough garage that it can sit in during the process. I hope you observed the tech do the work to learn more about the inner workings of your engine. I was extremely hesitant at first to tear into mine but now im comfortable just unplugging things and removing parts. Just stay organized and clean.

 

Yeah, if I had a big enough garage that I could close up and still have room to get around I may have made a run at it myself, ONLY because of the good people in places like FTE willing to share. I hung out for about an hour chatting with my diesel guy as he further broke down the upper engine parts to get to the valley. I learned what I could then realized I needed to get out of his way so he could get it done without my distracting him.

But another pressing matter was my wife's Sorento running very rough and quickly approaching the end of the powertrain warranty since we were solely reliant on it to get around. We want to use warranty coverage while we still can. Now that White Thunder II is up and running again we took the Sorento in for service this morning. It'll probably be maintenance items that I'll have to pay out of pocket, but I want to do all I can to keep her vehicle reliable. If one of us is gonna get stranded on the side of the road, I'd rather it be me.

Anyway, I intend to get with the guys at Gearhead this week for custom tunes to turn off my EGR Valve and hopefully smoother shifting than my current Innovative Agg Street tune. And I need to order up a "blue spring" kit. That seems like a very doable weekend warrior project.

 

One little side note : I found it helpful to have the engine up to operation temps before
putting the new tune on. That way you can go out and drive it. When I put the SRL on
I found that going out and taking the steps to do the trans relearn were very helpful
in getting the shift points right.


Sean

 

Thanks for the tip, Yahiko. I forgot all about the learning transmission. I guess I'd better read up on bismic's Torqushift Shift Relearning Strategy post.