First off, I've been a lurker for almost a year now, since I got my first (new to me) 2000 Excursion. Lots of great info and ideas here. I searched the forums, but have found nothing specific to my problems...

The vehicle is a 2000 Excursion 7.3 Diesel. I have never owned a diesel before....

First issue is that I have developed a hard start. It started last Saturday, and went from sporadically starting hard, to starting hard every time. I have 146,000 miles on her. She cranks strong, but will not turn over the first time, sometimes takes 2, 3, or 4 times. (Foot on gas pedal) I don't know if it's an issue of not getting enough fuel or what. Occasionally, even after she starts, it's very rough (shaking the whole vehicle, and acting like she wants to die) until I rev the engine and she smoothes out. After she smoothes out, there is no problem with wanting to drive, she's strong. If I kill the ignition, and start up immediately, she starts the first time, it's only after 10 minutes or so of being off.

My next issue is a clunking noise when I press the gas pedal. I don't know if it's the tranny, because she shifts pretty smooth for the most part, doesn't miss gears, etc. I could be travelling say 50MPH, press the gas pedal very little, and I can hear the clunking, and actually feel it every time I press it. (Don't have to be mashing the pedal, happens on very light presses as well).

I have the TS Performance 6 position chip, otherwise she's stock. I tow roughly a 7000 travel trailer every couple of weeks, never any problems before this. Any thoughts/info would be greatly appreciated. Thanks all.

 

Have you tested the batteries? Individually?

 

Cranks strong, but doesn't turn over? If it doesn't turn over at all sometimes and then cranks strong, check your battery cables etc.


Don't put your foot on the pedal to start.

 

Both batteries have been checked, they are good. Battery cables and terminals are good as well.

Perhaps I worded bad, I do not have my foot on the gas pedal when cranking, rather when it does finally turn over, I have to rev to keep it running until it smoothes out..if I do not, it either dies completely, or runs very rough to the point of rocking the entire truck, until it smoothes out on it's own, or I give it gas until it smoothes out.

 

So when you the key the motor turns over > rrrr rrr rrrr, but doesn't start? then when it finally does it runs rough for a bit? Might be glow plugs or the GPCM.

 

Does "check engine" light come on?

 

The check engine light did just recently come on. I just ran the code, and I have two issues:
P1211 which looks to be indicating the HPOP or Injection Pressure Regulator is faulty. (Quick Google search) I have no idea what to even troubleshoot here to figure that one out)

P0673 which looks like it could have anything to do with the Glow plug #3 circuit. I guess it could be the plugs themselves, or the glow plug control module. I'm guessing it's the module..

 

P1211 fault code is Injector control pressure higher/lower than desired (engine running)
How would I go about determining which is the problem?

Also just looked under the hood and found this:


That zip tie holding the harness to the GPCM probably isn't a good thing....


Also, I don't know if it is related at all, but my theft light has been flashing constant, even while driving.

 

Electrical gremlins...aarrgghh

What is your location?

 

I'm in Mass.

 

I could be wrong (unlike others on this forum) but it seems like you have more than one problem.

1. The tie on the electrical connections is a complete jack leg move.
2. Just a guess but I think there is some water damage/corrosion going on as well in/on the electrical connections.
3. Probably not the HPOP and more likely the Injection Pressure Regulator.
4. What is the gauge showing for volts while running?

I would start with the GPCM, but see what others say before "parts changing."

With more information I may modify my diagnosis.

 

Not sure what it should be reading, but on the torque app, the HPOP reading at idle was reading around 480, and around 25-2600 when I got on it.

 

Those are fine numbers for idle and WOT. With the P1211 code, pull the plug on your ICP (located on the front of the Drivers head) and see if it has oil in it. That will cause a P1211...

 

I think a dirty fuel filter will throw that code too. I think... How old is the fuel filter?

 

I pulled the ICP, no oil on it. Attempted to start with it unplugged, same hard start.

I crawled under the truck to see if I could figure out the clunking (which I think is the U Joints on the driveshaft) and I saw that there is a pretty good oil leak BEHIND the oil pan. The first thing I had to do to this truck was replace a completely rotted out oil pan (which required the engine to be pulled). It is now a leak behind it, is it a seal?