Replaced cups 3ish years ago
Replaced IPR (non- Motorcraft) and ICP last year
New (not remans) PIS Stage 1 injectors with Hydra Flash October

Truck has been running and starting (down to 19 degrees) like a dream since the new injectors. After the last fill up the truck has been harder to start in the morning and if I don't let it warm up till at least until the needle moves it will stall and be difficult to start. Once started and up to temp it runs just fine but will definitely take aa few extra turns to get started whether cold or hot.

There is CEL, I don't smell or see any diesel in the coolant, oil looks good and the diesel in the filter is kind of a clear blue? The way it acts when it stalls is kind of like when the IPR went bad the first time... kind of. The few times I was able to get my phone connected fast enough I saw and IPR duty cycle in the 90s flash and a HPOP pressure of 1500 or so flash all while the truck is barely hanging on to an idle.

Any ideas?

 

If its full on oil, after it stops, check the HPOP level. May be bad low psi pump.

 

Drop some orange power service additive (Called Diesel 911) in the tank and see what happens. Sounds like your jelling.


Denny

 

BTW, drain your fuel bowl a few times and correctly collect it. Surgically.

If you have a lot of water in your fuel, you just figured this out.


Denny

 

So it wasn't that tank of fuel but I have few more symptoms now and I meant to say there is NO CEL in the comment above. I know it isn't jelling because it does it even when it is 40 degrees.


While idling during warm up the truck will start fine and run for a few seconds then the IPR percentage will all of sudden start to climb up to the 80s or 90s until the truck starts smoking and shuts down. While doing this the ICP shows 600 give or take. Then the truck is pain to start while IPR is coming back down, once it warms all of the way up it runs great. Any ideas?

 

Have you tried while your ICP sensor is unplugged? Have you checked to see if the sensor is full of oil, indicating it is in its way out?

If you do have to buy any sensors at all, do yourself a favor and make things easier in the long run, buy only OEM sensors for your truck. These rigs do not like aftermarket sensors a lot of the time.....

 

I haven't tried that yet but I learned the non-OEM lesson the first time I replaced the ICP. I'll have to try unplugging it.


There is currently a used OEM ICP in the truck from last year when I got lucky enough to break down in front of a house in the middle of no where they had a blown 7.3 beside the person's garage. The non-OEM ICP had failed and shot almost all of the engine oil out of the top of the sensor.

 

well at least you got good pressure from the HPOP. 90% at idle? No wonder why she is choking and puking, what grade of oil you using? not getting any fuel in the oil are ya. look on the dip stick see if she is high and really thin, you may also get a wiff of diesel on the stick. At 90% 2800psi at the HPOP sounds like worn injectors bypassing, thats why she goes up. On a cold morning with heavy oil could be a problem as well, thick oil can't squeeze thru the poppet in the injector. Maybe 15W40 might be a bit heavy for your climate. Maybe a synthetic oil will help.

 

No, when it starts it is at normal IPR (15 to 17) for about 30 seconds and then all of a sudden will progressively start getting larger while at idle and the truck normally shuts down when it gets in the 90s.


ICP is around 600 or so at this point which is a little high for idle but not for first warming up.


I'm using Rotella 15w40 and the oil looks fine. They are brand new Oct 2016 (not remans) PIS injectors. HPOP will make 2800 when I open the throttle while driving and given that and the decent idle pressure I'm doubtful it is the HPOP.

 

Does this mean you replaced it because it was non OEM or with a non OEM IPR?

 

The IPR was replaced last year with a non-OEM IPR but I'm having a hard time believing it failed after a year and only 5k to 8k miles.

 

IPR's have been known to be bad right out of the box, so you may not want to dismiss this so quickly.

 

How cold is it where you live?
You did not state your mileage
It is normal for a diesel to lack a little power when cold.
Try plugging it in for 3 hours prior to starting and see if that changes things
Rotella Synthetic should make it easier to start. Not sure if you are using Synthetic or Regular
Have you checked the actual glow plugs?