Yes I know it's another no start thread..lol. Here are the details. Just replaced my HPOP, IPR and ICP and while driving at 75mph I hear a loud pop under the hood. Several seconds later CEL comes on and I have no power and the engine is shutting down as normal. I pull over, get out and there is a massive amount of engine oil everywhere, I get it and the first thing I look for is the HPOP area and the "non-serviceable" plug is GONE. I was able to find the metal piece that goes in between the plug and the ball, but no ball. I find the dimensions of the tiny ball (.25") and replace it. I order the long thread fix from RIFFRAFF install it and now I have a no start issue. While waiting for parts I change the oil and filter, clean the oil soaked engine and pray that nothing else was messed up. I do not have an AE or OBD-II, the truck has 300k on it and need a little guidance.

 

How long did you try to start your truck? The truck runs by the injectors being open by OIL pressure. When the non serviceable plug blew out and you lost oil pressure, the injectors closed and fuel was shut off and your truck died (this by product of shutting down will save your engine from melting down due to a lack of oil). The oil rails now have a lot of air in them and need to be purged out by cranking the engine and starter. When your oil pressure gets built up to open the injectors again, the truck should run. Know this though...the truck will run very crappy for about 50 miles until all of the oil is purged out of the lines.

 

Have your batteries charged up really well when cranking. The glow plugs will come on and pull the voltage down and with a lot of cranking, if the voltage falls below 10.5 volts.... it will not start.

 

I cranked for 10-15 sec at a time maybe 5 or 6 times trying not to burn up a starter in the process. When I changed the oil and filter I First filled the HPOP res. to just below the treads. It was in he upper 40's last night so I plugged in my truck anyway and that didn't help. I pulled the ICP to see if the oil rail had oil in them and it was full, I am about to see if any comes out when I crank. The truck ran as smooth as it ever has before this happened... Thanks for your help!

 

What the funny thing is that I had just bought 2 new Motorcraft not 30 min. before this happened.

 

There is air in those rails that needs to be compressed, keep cranking, 15-20 seconds let the starter cool for 45 seconds or so, do it again, rinse and repeat until she fires. She'll run rough for a while let her idle for 10 minutes, then take her out and run for 50-100 miles, she'll smooth out.

 

I just pulled the ICP off and cranked while my neighbor watch if any oil came out and yes there was oil coming out. Although there was not any smoke coming out while cranking.

 

Well sounds like the ICP is no good, but that's not why its not starting. ICP is not uncommon to buy a broken one. Don't know why but a lot of new ones fail. From what I understand its mainly aftermarket ones. You do have to crank along time to get the pressure back. Ive had to do it a few times and every time my batterys do not last long enough to get it going. I have a charger with a boost feature that I use to keep the amps up. If your starter is old, it takes even longer. That been said, I can't believe how many starters I 've seen burnt up from this procedure. So let it cool. 10 minutes of waiting won't effect your efforts. As said, its going to run like crap for about 50miles. I know a trick to prime the whole system without even starting the truck, and totally eliminates this issue. But I have never posted it because I know some one will mess up the process and ruin there pump. Its alittle tricky and if you don't make the jig right, then your rolling the dice. I usually prime it to about 2500psi, then its good to go. It still runs crappy for about 50miles though. Can't get all the air out.

 

When I unplugged the ICP earlier I did have a CEL come on. I have now cranked for close to ten times at around 10-15 sec each time and the batteries are still holding up perfectly, I have the truck plugged in right now although currently its in the upper sixties. This next round of cranking I will be putting on the charger just as a back up. Should I be concerned with lack of smoke while cranking? And yes Absolute I recently installed a new aftermarket ICP.

 

No smoke pretty much means theres not enough pressure for the injectors to fire. Have you checked all the basics. Fuel pressure, oil levels, leaks, something unplugged like IPR. Nut loose on IPR. Installed IPR with a wrench instead of a socket?? Werent expecting that one huh? Wrenchs kill IPRs. Socket Only. Was it clean and did you put the plastic spacer behind the o ring not in front. Haha. Seen that one. ICP un plugged throws a code so light comes on . My old ICP was leaking but you couldn't see it come out. If your buddy saw oil oozing out, then maybe that's why it has no pressure. Put your old one back in un plugged just to stop the leak, see if it goes. I would make sure I have fuel pressure too since you say you have been cranking a lot with no go. Open drain valve and turn on key while you watch for a good flow out the tube. Please catch it. Check your HPOP reservoir level too, before you start trying again. Maybe its draining back and you just keep filling it every 15 seconds. lol. I say check fuel just because your cranking a lot and no smoke. So if they are firing and no fuel?? Those are the two no smoke issued covered. Are you sure its cranking fast enough?? Mine wasn't, and I had no idea. Sounded fine until I put the denso in. Now I can't believe it.

 

I have now cranked it close to fifteen times @ ten to twelve seconds each with a five min. break. I just noticed that the glow plug light comes BACK ON while cranking. This is a first for me, also my son was watching the exhaust while cranking and observed a small amount of white smoke coming out at the end of the cranking cycle. Back to the glow plug light coming BACK ON...should I start looking at a glow plug relay issue or?

 

Small amount of smoke. Might be close. Stop that leak.

 

Ignore the glow plug issue for now. It's probably nothing.


You found a new check ball, but what about the edge filter? Read through these instructions and see if you notice anything you might have missed.

http://www.dieselorings.com/docs/service_plug.pdf

 

Oil level in HPOP res. is 1/2"-1" below threads, no oil of fuel leaks, IPR plugged in and installed with an 1-1/8" socket, no loose IPR nut, excellent fuel pressure, the oil oozing out was when I took the ICP out of the head just to check if I had flow to the oil rail, cranking is super fast and strong. One thing made me stop and think was when I checked the fuel filter condition, as I was unscrewing the cap fuel gushed out like I have never seen it before. HMMM

 

Will do thanks!