Ok, I have a few things I've noticed with my truck, and would like some advice. First off about my truck, It's a 00' with 240K, mods are 6637 air filter, exhaust, FRX from Riff Raff, and DP tuner, ATS ported compressor housing, with Riff Raff billet wheel for the ported housing.

On to my questions/issues, I've been having a starting issue for over a year now. If the truck sits for more than 10-12 hours it will start up, and only run for a few seconds then shut off. Then when trying to restart it, it will just crank, or briefly start and shut off again. The more days the truck sits the worse and more times it takes to start. I've noticed once the oil pressure gauge reads something it will start and stay running. I replaced the low pressure oil pump with a Melling unit about six months ago, and I thought it helped at first but it is still is acting the same way. I've noticed a few other things that may, or may not be related. The last two oil times I've changed the fuel filter it was fairly black kinda looked like oil, but not sure. Also recently my friend bought an 00' Excursion 7.3 and his injector cackle is much less than mine. One more thing that I just assume is normal, but when I turn the chip "on" meaning select any other tune then stock the injector cackle gets much much louder. I've never driving another 7.3 with a tuner so I've always assumed this is normal. I have the Torque app, and all the readings seem normal, the truck runs good, and gets right at 16mpg all the time. Any ideas, and advice would be great, and thanks in advance .

 

engine oil in the fuel filter [black fuel filter ],do a search on failed injector orings

 

I thought that might be a possibility, just was curious if anyone thought that things could be related.

 

Yes and the louder sound is do to the DP tuner increasing ICP pressure I believe. It is pretty normal with there tunes. I'd check O-rings and cups at the same time. Is your HPOP full after setting? It should be about 1/4 to 1/2 inch from the top.

 

I will check the HPOP reservoir. I figured the extra noise was normal, but wasnt sure. When checking the cups and O-rings, is it best to just replace the O-rings when you have the injectors out?

 

DP tunes the engine to increase atomization and power, and their technique makes the truck louder. While troubleshooting, pulling the chip helps... it eliminates questions like "Can it be the way the truck is tuned, or a connection from the chip to the PCM?"

Yours sounds like a classic case of tired injector O-rings and possibly injectors.

 

So do you think its possible the o rings are causing the starting problem?
Is there a way to check the injectors?

Thank you for the replies.

 

The starting sounds more like either an oil pressure, or injector problem. When I replaced my injectors I had a couple where the O-rings were nearly gone, but I had no starting problems. Only a nice blue smoke cloud when the engine first fired. A black fuel filter does point to high pressure oil making it's way into the fuel system, probably the O-rings.

 

The only way to physically check O-rings is to pull the injectors. Once you pull the injectors, you have to replace O-rings and the copper washers. In essence, I'm saying it sounds like the next step may be to order a full set of O-rings. [LINK]

 

After it sits for the 10-12 hrs again check the hpop reservoir for oil. If its lower than 1/2" from the top you have a possible drain back issue. It could be an injector(s) issue given the miles on them. The hard starts sure do point in that direction. This happened to my 03 Excursion when we had 3 failing injectors. Do you have a way to perform an injector buzz test or CCT? Best thing to do on the Hpop is to test what PSI its putting out. If it its 2800 or higher it may be just fine. Anything lower it won't be able to keep up. While starting watch the duty cycle of the IPR and the ICP pressure. The ICP should go to 2100 almost instantly. Let us know what you get. Doing all of this will give us good solid direction to help diagnose what is going on.

~Diane

 

Could be and that points towards injectors issues. These trucks weren't built to use Ultra low sulfur diesel so the O-rings become brittle and split over time.

~Diane

 

Thanks for the responses, I will check these things out that have been suggested and post back.

 

Ok, I couldn't get my HPOP reservoir plug out last night, so I couldn't check the oil level. I was able to check the ICP, and IPR duty cycle while cranking. ICP hit 2150psi max, and the IPR went to 47% these are using the Torque app. At idle the ICP is around 500, and IPR is 12%.

I have checked these two at WOT in stock tune, the ICP max is 2875, and the IPR is 37% max.
I plan on checking the HPOP oil level tonight and taking a video of what it does starting. I'll post more tonight.

 

It might help to tap the plug a couple times with a hammer before you try to remove it. Not too hard though, the housing and cover is just aluminum

 

Another trick that I have used to remove that plug is a fairly new vice grip pliers with the angled needle nose. This works to break loose the plug, but it can scar the lower face of the plug, so a fine file to polish it may be needed. The o-ring seals it, so the scarring does not compromise the plug. The plug does not need much torque to seal the o-ring.