Hoping to run this past you guys, been chasing a breadcrumb trail of worn out parts on this thing haha. Getting far closer to a solution but still not there yet. Father in law bought an 01 F250 with 350k on it in unknown running condition and Ive been getting it back on the road for him. Unknown maintenance history however engine is super clean under the valve covers so it has seen maintenance. I did get the truck started initially however it ran like garbage, missing, long start etc. Didnt pass buzz test on a few cylinders and with the mileage I decided to replace injectors in the thing. It definitely needed it, found multiple blown orings, leaking cups etc when i pulled them.

Got the new injectors/cups in and she fired right up after purging air from the fuel/oil galleys. Walked away while i was letting it warm up and came back a few minutes later to a dead engine. Found no RPM signal, CPS had failed (and its wiring was tore up). Replaced and sensor was reporting RPM. Still had a miss/hard starting issue after this so kept digging. Kept getting a P1273 code from the IDM and confirmed the harnessing is fine between IDM and all injectors. Did another buzz test and found #3 not passing. Swapped solenoids between 1 and 3 cylinders and found a bad solenoid on a reman injector as code followed the solenoid. Changed it out since they are cheap and buzz test is fine now, code gone. The engine fired up after 1/2 the cranking required before.

Still have a hard start issue after all of this. ICP sensor had oil wicking up through the sensor so it was swapped out, IPR was in poor shape and of unknown age when I pulled it so it also was replaced. Both IPR and ICP are Motorcraft aftermarket. After this, truck fires right up and sounds great. But wont restart when warmed up. Engine sounds totally normal when it runs but if its shut off its done till it cools. Let it sit overnight last night and it started no problem this morning.

Monitoring data last night when it wouldnt start, I was seeing ~2-400 psi of ICP pressure (80+% IPR duty cycle) when cranking which is obviously too low for the IDM to fire the injectors. Saw ~800+ this AM cranking and ~2600 full throttle so HPOP appears to be doing its job however I have not deadheaded it yet as I dont have the tooling to do so. Definitely have a high pressure oil leak somewhere in the system....

Unfortunately my FIL purchased reman injectors from Pensacola, Both of us were unaware of the issues they seem to have. My question is, is there a way to test these injectors for high pressure oil leaks pulled from the vehicle? I am a diesel mechanic by trade however dont have a ton of experience on the Powerstrokes, Im a JD guy (go easy on me haha). I highly doubt i cut or damaged any o-rings when I installed the reman injectors but I suppose its possible. I did order fittings etc to build an IPR air test setup to see if I can hear anything leaking by but itll be a few days till that stuff is here.

Im thinking Ive got a bum set of reman injectors dumping high pressure oil when hot, especially since one had a confirmed bad solenoid right out of the box. Would like to avoid taking them to the pump shop for testing but may end up having to do just that to get our money back from Pensacola, certainly not installing anything else of theirs if this does turn out to be bum parts. And of course they have our cores so this will be an interesting fight should it need to happen.....

Any other ideas other than a HP oil leak?


Cranking hot

~3/4 throttle cold

 

If the day ever comes, I hope I get a son in law like you.

Easy things to check first are the tin nut on the back of the IPR, and the solenoid coil it retains. Fairly common hot running issue. Tin nut can get loose or fall off, or the coil shorts when warm. You can ohm out the magnet, should be approx 10-11 ohms. Or when it fails hot, cool the coil an see if resumes working. Inverted can of air or cup of ice are the methods I read about, but I've never done either.

Hopefully others will be along with more ideas. Dead heading it would be next step imo.

 

Now this is interesting, found the HP oil leak tonight. I pulled the valve covers again and found HP oil leaks from the top O ring on ALL 8 injectors once the hpop reaches about 200psi. It does hold doing an air test with 120psi. Now the question is why, and why all 8.

Pulled injector #2 and O-rings were completely intact, no evidence of bypassing at all. I had 1 set of new Alliant o-rings so threw them on and threw #2 back in. Less leakage but still leaking somewhat.

Wonder if Pensacola polished or turned the exterior of these injectors? Wonder if someone else in the past did something to these injector bores?!? Suppose ill call Pensacola tomorrow and see what they say about it, id expect the injectors being out of spec to be far more likely than the bores but ?

 

Check the bottom of the cups, make sure there is only 1 copper crush washer down there.

Can't imagine taking extra time to turn the injectors, but who knows. Post up some pics so we can see them.

 

It got new cups when the injectors went in but i did check #2. Just one crush washer there. I think im gonna order 7 more sets of alliant o rings and see where i get with it. potentially have junky o-rings on the reman injectors? Will also reach out to pensacola tomorrow to see what they have to say as well...

 

I'm wondering if they are the right O-rings.

 

Supposedly Pensacola uses Alliant o-rings on their injectors so poor quality o-rings could be ruled out somewhat. Wonder if the cups didnt get fully seated? The Riffraff tool does screw them down to a hard stop at the bottom of the bores and wont turn any further so I doubt it but maybe??

Anyone have a depth measurement to the bottom face of the cup to the top surface of the injector bore?

 

You bought injectors from FL? Yikes! I hope they don't do this. We can test them for you if you need help.