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We took apart the IPR again, o rings good (replaced before) then we took it apart and cleaned it. It was pretty gummed up. Pressure is better, now reads at 230psi, but still not enough to fire. Any other suggestions?
your high pressure oil needs to be straight before we go any further. Are the batteries all charged up? just wondering if the engine is cranking fast enough. also are you positive the bolt for the HPOP gear is torqued down. I am wondering if it slipping. probably isn't but who knows. also I would try to swap the IPR with the other one you had. as 1997f-350 said you need about 500 psi to start these trucks. if your not hitting that mark then that is atleast one issue.
also verify the crank case oil level. then crank the engine for a while then check the HPOP reservior for small air bubbles. sometimes the oil pick up tubes crack and allow airation of the oil which could cause low HP oil pressure.if there are air bubbles add 2 quarts over full and jack the back of the truck up a bit. that will cover the pick tube with oil and allow it to draw clear oil.
checking bolt for hpop gear, it seems fine. We took the IPR out and cleaned it and replaced the o rings, it improved the pressure a little but not enough. There is air in the hpop reservoir, but when the engine was out the pick up tube was taken to the machine shop and it was good, there is also a new bottom end in it. Where else could the air come from??
Engine oil molicules all sheared down from being in the crankcase too long.
These PSD's are VERY finicky when it comes to quality oil in the crankcase.
When I was reading about changing the IPR it said that most of the oil in the hpop reservoir would drain out. I only lost about a tbsp of oil, and the reservoir is still full, does that seem strange? Also what about the seleniod for the IPR, could that be the culprit? I guess I am grasping here now!!!
As kwikkordead's reply, the oil in the truck is all new, the engine has only been in it for a week. Do you mean if the oil had been sitting for a long time? or low quality oil? We put good oil in it too, many oil changes in the last week, hoping something would help.
could be the solenoid on the IPR. can'tsay I have ever heard of one going bad but since you have one swap it out and see what happens. I will ponder this situation on my way to work and let you know if I come up with anything.
it very well could be the Hpop. I am not sure what to think about the oil not draining. when I changed my IPR o-rings I didn't get alot draining out but I also had a plug waiting to plug the whole. also it was too long ago to remember. If you still have another HPOP laying around give it a try. just remember to refill the HPOP reservior and it will take some time to crank it back up after the change.
What about the air in the hpop reservoir? Could it be coming from somewhere else? I don't thing it is the quality/age of the oil. Its new oil and it is diesel rated. The oil in not foamy/airated, it just seems to have larger air bubbles in it.
has this engine been running since installed or is the the initial startup? How much air is in the HPOP reservior? also pull one of the high pressure oil galley plugs on each side and verify the heads are full of oil. these plugs will be inline with the hose coming from the HPOP. double check the reservior oil level. should be full within one inch of the top.
you also said that the tach is moving while cranking right? Can the scanner you have do a buzz test. This is an electircal test of the eletrical side of the injectors. it will actually buzz, rapid on and off, the injector solenoids.
Where are you located? maybe somebody is close to that might be able to help.
Don't get discouraged either. we always get them fixed!