Hi!! I hate to start out my first post with a problem, but I just had my truck die on me two weeks ago. I had bad fuel in the truck a year ago, and the injectors slowly got worse and worse until I couldnt drive it much more.

I have a 1996 F250

Last week I replaced the injectors, glow plugs, gpr, cps, fuel pump, cleaned the fuel bowl, rebuilt the oil cooler, and some other little things here and there.

After two days of working on the truck, I am excited to start the truck up!!

Nothing. cranking and cranking for hours not even a blip of wanting to start.

After searching for days on all sorts of forums and google, I could not come up with any conclusive info. I am trying to get a mechanic with a scan tool to come out and help, but I was hoping someone here could help since this seems like the best forum for these trucks.

So here's everything I've tried:

Disconnected the fuel bowl heater, switched cps, I get oil pressure (dummy gauge) I get WTS light, I checked all fuses twice, unplugged ICP.

The fuel bowl is filling, (perhaps slowly?? not sure)

I lost a small yellowish ball (slightly larger than a bb) from somewhere in the fuel bowl or fpr. It just fell out when i pulled the fuel bowl assembly. The plunger in the bowl works and no leaks. I replaced all hoses with blue ford hoses...

I pulled the serp belt and thought maybe i bumped the cps since I havent gotten much tach movement...I also thought the clip on the fuel bowl harness ( the larger single plug end on the passengers side) had the clip in a different spot, so I yanked the cover for the clip itself (where the wires enter the actual clip) and thought that might have caused a short or no contact? I tried the fuel bowl heater, and no oily plugs. Could it be the harness or did I knock the ipr and not notice while I was working in the valley?

I am at a loss, no smoke and cranks and cranks? the cranking does have a bit of a miss in it, like bum bum bum bum bada bum bum, did I hydro lock it or something? why nothing more than a blip on the tach with a new cps? no smoke though?



Please any help is greatly appreciated!!
THANKS!!!!

 

Did you find the yellow/white ball from the fpr, and replace it? That little ball is very important. If it is still missing, I don't believe you will build fuel pressure. No fuel pressure = no start.

 

No I did not, Maybe this is my problem...does it go behind the fuel return screen? I tried it there, then nothing changed, so I took it out and still nothing....thats when I lost it late at night....Do you know where exactly it goes and where I could get another one? Thank you very much!! that was a really quick reply

 

I had looked all over online and only came up with the bb shim mod

 

 

Fuel Regulator Repair Kit

 

wow thanks!! I could not find the fpr rebuild on their site, just the drain valve rebuild on the fuel bowl...thanks!!

but that still brings my back to my original problem...It wouldnt start or smoke even with the ball in the right place in the fpr....I took it out after it wouldnt start thinking i put it in the wrong place...

 

The entire process
http://www.dieselorings.com/docs/OBSFuelBowlRebuild.pdf

 

Just a few questions if you still have problems after getting the fuel pressure regulator back together.

Did you take out the oil galley plugs on the heads before removing the injectors? If so, did you make sure to put them back in?

Did you check the HPOP and see if it is full with oil? When the injectors come out, that HPOP reservoir is going to drain down. With how much cranking you did, it should have filled up by now unless something wasn't put back together.

Also, what was your process for evacuating the cylinders? I ask this because when I evacuated mine, I removed my IDM fuse so I can crank the engine over with the glow plugs out (after I cranked the engine over by hand.) If you did this like I did, did you make sure to put the IDM fuse back in? (or any other fuses you may have taken out along the way?)



Your truck definitely won't start until you get the fuel pressure regulator back together, but I'd figure I'd ask a few things in case you still have trouble!

 

I did take the oil plugs out of the head, and remembered to put them back in because the instructions swamps sent reminded me like three times lol. I did check the HPOP, and it was not even low on oil after cranking a bunch.

When I was done with the injectors, I left the glow plugs out, turned the engine over by hand a bunch of times, and then left the ucvh harness unplugged, cranked the engine over maybe 2-3 times, then installed everything and tried to start it up. I've double checked any connections that I messed with during the install.

And with the FPR, I had the check valve ball installed correctly when I first tried to crank, and even cranking for hours I got no smoke. That is when I decided the ball must not belong there and removed the fpr and the ball and lost the ball, but still tried cranking and no change. so I have ordered that fpr kit waiting on that, but since I had the ball in the right place in the first place, I am kinda lost. I have a guy with a scanner coming to help me scan it tomorrow night, hopefully that will point me in the right direction.

Thanks Bubba