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1999 F350, 4x4, 7.3 Powerstroke diesel, auto trans
Cab and frame were rusty, so we swapped everything over to another (rust free) cab. *Everything*, wiring, interior panels, seats. Also repaired the rusty spots in the frame while the cab & bed were off.
The engine had a bad piston, so we bought a professionally rebuilt long block assembly. Swapped over all of the needed accessories, manifolds, etc. Had the fuel injectors tested (all good), replaced the o-rings when they were installed into the engine.
Fast forward to trying to get the engine to start. It cranks fine, but doesn't make any smoke, doesn't start.
Scan tool runs the injector buzz test and they all sound normal.
Engine oil pressure is OK when cranking (just above the 1/2 mark on the gauge).
Scan tool shows cranking speed of about 150 RPM. No codes in PCM memory.
Checked the connector at the IPR - solid battery voltage on one wire, the other wire has continuity to pin 83 at the PCM.
We have a running 2000 powerstroke truck that we've been borrowing parts from and also using it to test the suspect parts. The "suspect" PCM does start this truck, so it's no longer "suspect" for this problem. The PCM from the spare truck does NOT start the problem truck.
While cranking, the scan tool shows "INJ REG 32%", "VOL FUEL 68 mm3", "FUEL PULSE 3 ms", "INJ CTRL A 2288 psi". This last one is impossible, since there is NO oil in the high pressure cylinder head galley. If I unplug the IPR, the "INJ REG" climbs up to 85 while cranking.
Connected my multi-meter to the IPR control wire and ground, put it in hertz mode, got 0.00 reading while cranking.
Good ground wires at PCM pins 51, 77, 103, 25.
HPOP reservoir is filling (checked through the allen plug on the top).
New pressure sensor & connector wire.
New IPR solenoid. Also tried 2 used ones that measure 10 ohms resistance.
Tried 2 (used) HPOP pumps, including the original one from before the engine was replaced. (It ran, but was not happy because of the bad piston)
Made an adapter & gauge to thread into the pressure galley on the left cylinder head. The engine has *zero* HPOP flow or pressure.
I have heard that HPOPs go bad often, but I find it hard to believe 2 of them failed completely. I'm going to take one of them apart tomorrow at work.
Any other ideas? I'm fresh out.
Many thanks in advance!
Almost sounds like you're air locked. Can you disconnect a high pressure hose to see if you get any oil? It should gravity feed it's way out provided the exit is lower than the oil level in the res. Another thing just occurred to me. Any chance the gasket slipped during install and it's actually blocking the inlet port on the pump? Was any servicing done to the pump while it was out?
Oh you might also want to check out the tech section here and read up on the Forscan app. It is the best diagnostics software available for any and all Fords. The price is free on PC and $5 or $6 on Android app store. It is a must have when it comes time to start digging into these trucks.
It's gear driven from the camshaft drive gear. I torqued the bolt to 95 ft-lbs (as recommended in another thread on this site).
I'm wondering if there is something going on within the HPOP reservoir, that's blocked the oil from entering the HPOP pump.
>> Almost sounds like you're air locked. Can you disconnect a high pressure hose to see if you get any oil? It should gravity feed it's way out provided the exit is lower than the oil level in the res. Another thing just occurred to me. Any chance the gasket slipped during install and it's actually blocking the inlet port on the pump? Was any servicing done to the pump while it was out?
I had the pressure sensor out and there is zero oil inside the high pressure galley. I thought of the gasket because if it rotates slightly, the bolt holes in the pump will line up with the oil holes in the gasket. But it's very obvious when that happens. No servicing was done to the original pump. My buddy (who owns the truck) swears by afterarket pumps, so he's going to buy one. It'll probably be 2 weeks before I'm back at his place to install it.
>> Oh you might also want to check out the tech section here and read up on the Forscan app. It is the best diagnostics software available for any and all Fords. The price is free on PC and $5 or $6 on Android app store. It is a must have when it comes time to start digging into these trucks.
How long since the pump was in use? If you or him saw it run ever, and it hasn't been sitting under a gutter down spout for 5 years or in a vat of acid then it should move oil. Like I said it should gravity through given enough time. I would probably pull a line right at the pump or pull the IPR valve. That would defiantly let you know if oil is getting inside the pump. If it's getting in then the pump will push it on through. The way they are designed the pumps will continue to move fluid right up until complete catastrophic failure and it will let you know when that happens. Just my 2 cents, end of the day it's his money to spend however he likes. Oh and any and all aftermarket pumps are used rebuilds of one fashion or another, some done well, many many others not so well.
>>How long since the pump was in use? If you or him saw it run ever, and it hasn't been sitting under a gutter down spout for 5 years or in a vat of acid then it should move oil.
Agreed! It's been about a year and the HPOP was sitting on a bench inside the shop. It ran good enough to drive the truck in, so it ought to be good enough to drive the truck out.
>>Just my 2 cents, end of the day it's his money to spend however he likes. Oh and any and all aftermarket pumps are used rebuilds of one fashion or another, some done well, many many others not so well.
I'd guesstimate that he got $20K wrapped up in this truck, so another $800 or so isn't going to phase him at this point.
>>Sorry but my ADHD won't let me read that OP but I think I'm seeing 2288 for ICP. If I'm wrong, please do help me understand. Sorry but my ADHD won't let me read that OP but I think I'm seeing 2288 for ICP. If I'm wrong, please do help me understand.
Your eyes are not deceiving you, but the scan tool is. It's showing pressure, but there isn't any. The sensor is out of the head and I can look into the oil galley, it's empty.
You can click the "Quote button to quote the post you are referencing, for easier use. So, is there oil in your HPOP reservoir? I believe that you can pull your IPR and verify that oil is flowing out of the reservoir to the pump. Have you verified that the check-ball is in the block, behind the HPOP?
You can click the "Quote button to quote the post you are referencing, for easier use. So, is there oil in your HPOP reservoir? I believe that you can pull your IPR and verify that oil is flowing out of the reservoir to the pump. Have you verified that the check-ball is in the block, behind the HPOP?
Yes, checked for oil in the reservoir by removing the allen plug on the top of the reservoir. It was full.
If I pull the IPR, won't it make an even bigger mess in the valley than the mess it's already made?
I don't remember seeing any check *****. Are you talking about the one shown in this discussion, about 1/2 way down? (Pictures of HEUI HPOP disassembly for International / Navistar 2001 DT466E Engine (videoflier.com))
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New engine, No HPOP pressure
