The check ball should be trapped behind the pin of the "non-serviceable" plug. If it was in your IPR, it is on the wrong side of the pin and you will not develop any pressure from the pump. That is why it is important to have the pump in the correct position, snap ring side pointing up, so the check ball does fall out of the open port or move into the IPR when servicing the plug.

 

Good info Bob. Thanks.

 

I found the check ball buried in the IPR. Used some compressed air to get it out. Put it back where it is supposed to go. Reinstalled my pump. Dropped an inspection plate screw that I still can't find and installed the fuel bowl assembly. D@mn the luck.

 

I got everything back together, except for the inspection plate on the front of the reservoir. I still can't find the bolt that goes in there, looked for 2 hours. Anyone know a good place to get them or what size/thread type it is so I can find it at a screw store. Hopefully this will be the last question.

 

Take the one you still have with you and match it at Lowes or an industrial faster store like Fastenal. They can measure the thread size.

 

Didn't even think about that. Thanks.

 

bump.....whats the outcome?

 

Found a bolt at Napa. Got it all put back together. Won't start still. For what its worth, the magic check ball in the pump is a 1/4" plastic ball, same as in the Ford transmission valve body. So if you lose yours, look at a tranny shop. The local one here gave me one for free before I found where mine was stuck.

As far as the truck not starting. I have hooked it up to a battery charger to make sure i had juice. The fuel bowl filled itself, so I know i have fuel. I filled the reservoir, and it finished topping itself off, so I have oil. The low pressure gauge in the cab is looking good. I have rechecked all the electrical connectors, cleaning them with brake cleaner. This is where I am stuck. I usually do ok with replacing broken parts, but I am not much for trouble shooting. I work for an ambulance company, the the company mechanic said he will look at it Tuesday for me. I am hoping it is something stupid I forgot to check. I don't have any way to check oil pressure out of the pump to make sure I am getting what I need to work the injectors. I don't have a multimeter either. I have checked the fuses and they all seem to be ok. I have cranked it on and off for an hour or so.

 

BUMP....What did the mechanic have to say and what headway have you made?

 

He said it is somehow electrical and suggested I change out the IPR. He even had on in the shop they won't use anymore, so I got it free. I just got it changed out. It still won't start. The check ball is still in the right place. I am getting fuel. I filled the reservoir prior to turning it over. I charged the batteries. Checked all the fuses. I was thinking maybe a burned out fuse for the fuel bowl. No such luck. Although I am not getting power to fuse 30, 31, and I think 32 if I remember right. My truck is a 2002, and fuse 30 isn't for the fuel bowl like for other years, it is for High beams. I don't remember specifically about 31 and 32, but 30 for sure isn't getting power with the ignition on. He hooked a computer up to the data port and it said I didn't have any oil pressure. He wanted me to change ICP sensor if the IPR didn't change anything. I need to wait for payday to buy one. Any suggestions on where to buy one or other things to check. i have all the electrical connectors in the right place and I cleaned them out. I want to get a fuse tester to recheck them. I am a paramedic and had to run a call part way thru him looking at my truck. He wasn't able to dig in too deep since he was on the clock, but at least he was nice enough to give me some direction. What do you all think?

~Brandon

 

UPDATE: long story short, i changed my "non-servicable" plug o-ring. Put it all back together and it won't start. Check ball is in the right place. I changed the IPR and the ICP sensor. Hooked it up to the battery charger just to make sure. Turns over great, but won't fire. Not blowing any smoke. Fuses are good. Any suggestions? I am at my wits end. My truck has been down for over a month now and its killin me. I'm wondering if my pump went out, but I have no idea why taking it out would make it stop working. The only wierd thing I notice is that the oil drains out of the reservoir.

 

Got it figured out. It was 1 of 2 things. It is possible that I had one of the spring backwards under the plugs that connect to the high pressure oil lines. It flew out, but on its way out I thought I noticed it was backwards. The other potential issue what a little steel ball bearing that sits under a triangle piece of metal behind a spring behind one of the plugs. The little ball bearing may have been slightly out of place. Either way, I got it back together and it runs like a champ. Thanks for everyones helps. Saved me a ton of money.

 

And the Saga comes to an end. Good for you bfog99. Your perseverance paid off. Thanks for all your updates.

You now probably know more about the HPOP then 95% of us.

Did this also cure the HPOP reservoir drain down?

 

I actually fixed it this morning at work and once it was running I wanted to give the RTV goo time to dry, so I haven't checked back yet. I will in the morning and let you know. I got pretty good at taking the pump out. I can have it out in about 10-15 minutes and reinstalled in about 20. It is tough with big hands.

My one word of advice... don't drop the little bolts on the inspection plate. They can be a bugger to find. AND it is a lot easier if you disconnect the sensor on the inspection plate instead of try to fight the metal tubing attached to it.

Thanks again for everyones help. It was truely much appreciated.

~B