My 1996 E350 7.3 powerstroke sputtered and would not start. Sputtered again, started and sputtered, ran for 20 sec. and quit. Now it just will not start.

What I've tried: Drained some fuel from tank to check for water, changed fuel filter, drained fuel filter body and refilled w/good fuel. Filled my HPOP reservoir and cranked, got 2 or 3 sputters. Then I rechecked the HPOP reservoir and have found it is low after just a few cranks. Filled it again,same thing, low again. After 3 or 4 repeats of this effort, my oil in crankcase is now above the full mark ( was at the fullmark when I started all this). Temp outside is 40 deg. +/- and I have used the block/water heater just in case. Truck is a "sold as incomplete" motorhome chassis with 16 ft. box added w/econoline cab. Fuse panel has 18 fuses (except no #13 fuse)205K miles, ran fine when last used a month ago.

I would appreciate any suggestions.

 

Welcome to FTE.

You overfilled the crank case by topping off the HPOP reservoir a few times? How much oil did you put in there? You do know you cannot fill it all the way up, right? How low does the oil in the reservoir get? If it pumps itself empty, then I'd say you've got an IPR issue, LPOP issue, or cracked pick up tube. If it's only an inch low after cranking, we need to go a different direction.

 

I've been filling it approx. 1/4 in. from top. After just a few cranks, it is down maybe 15-20 oz. ( an estimate-not measured). What is the LPOP and IPR? Thanks.

 

There's a standpipe inside there that drains excess oil back down into the crank case as you pour it in. If you pour slow enough, you could dump 15 quarts in there. The full level is around 3/4" - 1" from the top, so it sounds like the oil level in there really isn't dropping. LPOP is low pressure oil pump and IPR is injector pressure regulator.

Does your WTS (wait to start) light come on with the key? When you're cranking, is there any smoke coming out of the tail pipe? If you haven't driven in a month I'm guessing you have another vehicle. Have you tried to jump start it? Just because the motor spins doesn't mean you have enough power to operate the glow plugs and fire the injectors.

 

OK, now I am sure I've exceeded the standpipe height, thanks for educating me on that. I am going to drain some oil to get down to the full mark before something else bad happens when I finally get it started. The WTS light does come on, no smoke is coming out of tailpipe. With this vehicle, I typically only use it 1, 2 time per month, used as a carrier for my off-road bikes/camping vehicle. Its never been a problem previously. Once, my son (the previous owner) had a similar (same?) problem and the mechanic simply refilled the HPOP reservoir and it started fine. That's why I went in that direction. I have trickle charged both batteries to full and it cranked fully and cranked and cranked, so it does not seem that battery power is the problem.

 

is your tac moving when you crank it over. If not could be your CPS (cam shaft sensor)

 

No smoke out the tail pipe and the batteries fully charged, this is my next question as well. Does the tach move while cranking?

 

Do you have fuel pressure. You can check it with tire gauge (100psi gauge)at the schrader vavle on the drive side of the fuel bowl while some one cranks it over. I think you need at least 25 psi. to run no more than 75 psi.

 

why do you guys keep on asking if there is smoke coming out of the tail pipe while he cranks? when I crank my truck smoke doesn't start appearing until maybe 5-10 sec of cranking. Once the smoke starts showing up I know she's close to cranking

 

Because if there's no smoke at all coming out of the tail pipe while cranking, then that means the injectors are not firing. Could be the IDM is not commanding the injectors to fire due to low voltage or some other issue, could be low engine oil or lack of fuel. Could also be an electrical or CPS issue. Smoke coming out the tail pipe eliminates a lot of things.

 

The truck has no tach. Its an Econoline e350 powerstroke with a 16 ft. box (Marathon).

 

OK, that helps me unerstand as I have suspected no fuel flow allt the way to the cylinders, but kept focusing on the tank, filter,etc. Wish these came with elec. fuel pumps, that tank is a long way back there.

 

you could try sticking a CPS and see if that works

 

Chis , from the diagrams I have seen, both stand pipes are "oil in", how is the oil getting to the c case from there (without the IPR dumping)?

 

The pump's not running Rick. When the engine is on, the stand pipe is oil in. With the engine off, there's no back flow valve so oil will drain back down through the lpop.