Air Test
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From: Kearns, UT
Air Test
I am working my way through diagnosing a crank, no start on my (late) 2004 6.0. Torque Pro shows the HPOP is only producing 230psi, IPR is 83.9%. All other readings are where they should be.
I am about to do an air leak test. Is there a certain PSI I should stay under while performing the test? My air compressor is normally set at 120psi.
Thanks in advance for your advice!
I am about to do an air leak test. Is there a certain PSI I should stay under while performing the test? My air compressor is normally set at 120psi.
Thanks in advance for your advice!
Fleet Mechanic
Joined: Jul 2018
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From: Jacksonville Florida
The system will take 120 psi. It operates with way higher psi. I would listen around the filter housing for a gurgle sound. That would be a bad pump. 2003 and 4's are famous for bad pumps. I've done mine and had same symptoms.
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From: Kearns, UT
I've done the air test through the ICP port and through the IPR port while listening with a mechanics stethoscope in the oil fill on the passenger side valve cover and the crankcase vent on the driver side valve cover.
Through the ICP port, I heard a small amount of air, and when I energized the IPR valve, the sound of the air changed. Through the IPR port, the sound of the air was much louder and I felt the air come up through the stethoscope into my ears.
I guess this means the valve covers are coming off......
but it's the only way to really solve this.
Through the ICP port, I heard a small amount of air, and when I energized the IPR valve, the sound of the air changed. Through the IPR port, the sound of the air was much louder and I felt the air come up through the stethoscope into my ears.
I guess this means the valve covers are coming off......
but it's the only way to really solve this.
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From: Kearns, UT
JOHNSONJF - Sounds like the predicament I'm in. I replaced the junk Ford reman HPOP with the DieselSite Adrenaline pump along with discharge tube, nipple cups o-rings and all the things you did. It ran like a champ for 8 months and one day would not start. As soon as I get mine running, I'm selling it.
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From: Kearns, UT
I found my HPO leak, #8 injector. The top o-ring, spacer, and clip were broke in half. I'm not sure how in the world that happened. Last year when I installed the Adrenaline pump, I replaced all the o-rings on all of the injectors, along with the o-rings on the nipples on the oil rails and other related parts. I'm just not sure how I made that happen. I'm going to purchase a replacement injector from one of the local Ford dealers tomorrow and redo the air test.
On another note, introducing air through the IPR opening did nothing to pinpoint the leak. It sounded like the air was dumping into the inside of the engine. Once I applied air to the oil rail itself, that's when I found the leak.
On another note, introducing air through the IPR opening did nothing to pinpoint the leak. It sounded like the air was dumping into the inside of the engine. Once I applied air to the oil rail itself, that's when I found the leak.
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From: Kearns, UT
You are correct. The real test fitting doesn't have tiny holes around the side. Hence why my homemade version didn't work.
Thank you for pointing that out! I've now ordered an actual test fitting.
Thank you for pointing that out! I've now ordered an actual test fitting.
Tuned
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Good Luck
Jeff
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From: Kearns, UT
I feel like I'm playing wack-a-mole with air leaks. After replacing the profusely leaking #8 injector, I put the oil rail back on all torqued down and applied air through the IPR port with the proper test fitting. There is no audible air leak to the naked ear, but with a mechanics stethoscope, I can hear a faint air leak at the top of injectors 2, 4, and 6. Injectors 8 and 1, 3, 5, and 7 are not leaking. I'm tempted to put it all back together and give it a crank. But I'll pull the oil rail back off and take a closer look at the o-ring on top of injectors 2, 4, and 6. ALL the o-rings on all the injectors were replaced 8 months ago with the Alliant Power AP0002 kits and the nipple o-rings (HHC Diesel) as well.
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