2003 HPOP installed, no start
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2003 HPOP installed, no start
Truck has 168K, removed original HPOP pump and replaced with Adrenaline stock output unit and new Ford J tube. Installed new Ford IPR and ICP, oil cooler, blue spring kit, serpentine belt. Replaced every o-ring and gasket I could so as to just do this once. When assembly was completed, I set a battery charger on it and went to lunch. Cycled the fuel pump about six times to prime fuel system. Lots of cranking but no fire. Oil pressure registers on dash gauge, oil filter housing is full, fuel filter housing has fuel. My TorquePro display on my tablet is not extensive, but I saw FICM 48.5V, HPOP 312 psi and IPR 84%. I know it takes 500+psi to fire the injectors; what I don't know is whether there is some electric component not functioning cooperatively or a massive oil leak on the high pressure side. There are a grillion possibilities, so I'm looking for wise counsel on where to begin to look. If it was your rig, where would you start? I appreciate everything I have learned thus far from you guys.
Fleet Owner
Joined: Nov 2003
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Might be worth pulling the IPR valve again and seeing if there is any (new) trash on the screen.
Did you replace the screen under the oil cooler?
Prior to replacing the pump, did you clean out the path between the oil cooler sump and the HPOP?
What led you to replace the original HPOP?
Did you replace the screen under the oil cooler?
Prior to replacing the pump, did you clean out the path between the oil cooler sump and the HPOP?
What led you to replace the original HPOP?
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I used the Dieselsite o-rings.. Yellow below pump and black between pump and J pipe. I can't remember now if the o-rings were in Ford packaging
J pipe had the o-rings installed by Ford. D ring above and the backer ring and o-ring in the tube.
J pipe had the o-rings installed by Ford. D ring above and the backer ring and o-ring in the tube.
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I did replace the screen under the cooler. The old one was intact but there was debris in it.
I did scrape and blow out the crud along the HPOP cover and oil cooler cover.
There's a long story behind this but in short, the previous owner threw a ton of parts at this truck and gave up. It starts easy, but once warm, if you put any kind of load on it , it quits. For instance, when warm, I can leave my house and drive a mile and start to pull a hill. IPR % is roughly 50-55% and then instantly spikes to 85% and quits. Sit for 15 minutes and let it cool down and it will re-start. If you try to re-start right after it quits the HPOP pressure is around 300 psi. The folks i talked to (ford diesel mech and others on the board) felt it was time for a pump. So here I am.
I did scrape and blow out the crud along the HPOP cover and oil cooler cover.
There's a long story behind this but in short, the previous owner threw a ton of parts at this truck and gave up. It starts easy, but once warm, if you put any kind of load on it , it quits. For instance, when warm, I can leave my house and drive a mile and start to pull a hill. IPR % is roughly 50-55% and then instantly spikes to 85% and quits. Sit for 15 minutes and let it cool down and it will re-start. If you try to re-start right after it quits the HPOP pressure is around 300 psi. The folks i talked to (ford diesel mech and others on the board) felt it was time for a pump. So here I am.
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Fleet Owner
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The IPR spiking suddenly sounds more like the IPR or the IPR wiring (or ICP and/or ICP wiring) than it does an HPOP. That said, you now have a new IPR and a new ICP. Did you change out the wiring pigtail on either of them? Remember, the IPR % duty cycle is simply a commanded value. It does not represent an actual valve position. Anytime you work on the high pressure system, it is VERY easy to introduce new contamination.
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Our plan is to pull the IPR and verify the screen is clean/dirty and replace the pigtails on both the IPR and ICP. Gotta wait a week before I get back at it. I'll post what I find. I certainly appreciate all of your help!
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Joined: Sep 2016
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From: Texas
I wouldn’t cut and splice the pigtails until I verified the IPR screen is clean and that’s not the issue then if it still doesn’t work then maybe patch the connector that’s bad. It’s not that hard to get to the IPR and ICP from the top and mine is a 2003 with the ICP under the turbo. All that nonsense trying to reach them from under the truck is too time consuming in my opinion.
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