Crank No Start After Reconditioning Turbo - HP Air Leak
This is my first post and I usually just lurk around to find all my answers, but this one has me stumped. I apologize in advance for the long first post. I also have this cross posted on ps.org.
Vehicle: 2005 F350 6.0 with around 110k Miles. I just recently performed an Oil Change and did Fuel filters at the same time within the last 1k miles. I do Oil Analysis at ever oil change and aluminum levels have been climbing but Blackstone Labs didn’t see a concern at this time. There’s no coolant in the oil and flashpoint and fuel % were OK. It all started with a P0299 code that I was looking to correct after a while of needing attention. Other than that, the truck runs like a top with no other codes. I managed to pull the turbo out, take it apart and recondition it following all the guides and videos I found on the internet and these forms. After reconditioning, I opened the inspection port on the valve and checked that the vanes where functioning as they should and all was good there. I put everything back in the truck, replacing the orings that came with the turbo mounting kit and installed the updated oil supply tube after installation of the turbo. I buttoned everything up, connected all the plugs and went to fire her up and it would crank and not start. It didn’t even try to start or run at all. I hooked up my AutoEnginuity (AE) Scan Tool to check the vitals:
Ed from FICMrepair just rebuilt my FICM and I’ve confirmed that to not be the issue. The truck has brand new batteries and a new DC Power Alternator with the Big 3 upgrade. So I thought I had an issue with the IPR as I could have very well got some junk in the system when installing the turbo drain line back in. I pulled the IPR, and the screen had zero defects, so I replaced the screen and orings anyway and reinstalled back into the truck. The truck would still only crank and not start. I then pulled the ICP and hooked up shop air to the system, opened the Oil Fill Tube and the vent line on the driver’s side valve cover was open since the air intake is all removed. When pressurizing the system to 100+ PSI, you could hear a hissing/gurgle from the Oil Fill Tube. I tried a KOEO and listened to the hissing/gurgle and it had stopped. I also commanded the IPR to 100% via AE for a short duration and there was still no hissing/gurgle noise. I pulled the keys, and the hissing/gurgle noise came back. This is currently where I’m at in this whole ordeal. This is not my everyday vehicle so nothing is a 911 as of yet although I really want my truck back up and running. I’m open to ideas on what I should check out next to pinpoint my issue or if someone thinks I’ve overlooked something simple, please call me out on it. So here are some questions I have:
Any help or advice is definitely appreciated. Thanks! |
Should have been no issues with a simple Turbo R&R used you disconnected several connectors or caused a vref wire to chaf messing with all other sensors down the line.
Got fuel pressure? Josh |
Originally Posted by Bullitt390
(Post 14708783)
Should have been no issues with a simple Turbo R&R used you disconnected several connectors or caused a vref wire to chaf messing with all other sensors down the line.
Got fuel pressure? Josh I went through all the relays and fuses including ones for the fuel pump and all was good there. I checked for chafing in the "usual" areas but nothing to cause concern and also moved the wire looms around to see if it would magically start because of it. No dice. |
It may just be coincidence who knows.
Dumb question as I am not to sure about the readings you posted since I don't know much about AE-but did some way or some how the IPR come unplugged? It's right there and could easily happen. Doing a turbo R&R does not have an effect on HPO as far as I know |
Originally Posted by 2006powerstroke90
(Post 14708853)
It may just be coincidence who knows.
Dumb question as I am not to sure about the readings you posted since I don't know much about AE-but did some way or some how the IPR come unplugged? It's right there and could easily happen. Doing a turbo R&R does not have an effect on HPO as far as I know Unfortunately it was completely plugged in and AE was reading voltage on the IPR and it was running at 85%. I've since taken the IPR completely out and there was no damage to the screen at all and the valve seemed to be functioning just fine with the correct resistance across the terminals. I replaced the IPR screen and orings for good measure and tried again with no luck. Then went to the Air Leak test where I heard a leak and when commanding the IPR, the noise stopped. That's where I'm current stuck. |
If you heard air then there is a leak...
Could be the STC fitting, or stand pipes/dummy plugs....any idea where you heard air from? |
You're going to hear a leak until the IPR is commanded closed. That's the reason for commanding it closed, otherwise air is exhausting out the IPR bleed port.
Josh |
Originally Posted by Bullitt390
(Post 14709692)
You're going to hear a leak until the IPR is commanded closed. That's the reason for commanding it closed, otherwise air is exhausting out the IPR bleed port.
Josh |
Originally Posted by 2006powerstroke90
(Post 14709657)
If you heard air then there is a leak...
Could be the STC fitting, or stand pipes/dummy plugs....any idea where you heard air from? |
Originally Posted by WaistDownUnder
(Post 14709911)
I heard the air coming from the Oil Fill Tube with the key off. When I turned the key on there was no more leaking air sound. There was also no more air leak when I commanded the IPR to 100% with AE.
Also, the injectors will exhaust air past the spools until KOEO which energizes the coils closed. If you have no air leak with IPR commanded 85-100% and KOEO you have an issue elsewhere. Josh |
Originally Posted by Bullitt390
(Post 14709930)
Yes it will leak unless the IPR is commanded on.
Also, the injectors will exhaust air past the spools until KOEO which energizes the coils closed. If you have no air leak with IPR commanded 85-100% and KOEO you have an issue elsewhere. Josh Next step... new IPR Valve? Or do you suggest testing something else in the system? Would a Bad IPR Valve read 85% when cranking and only allow 400 psi to build? |
You're not using a Motorcraft filter with a NAPA oil filter cap are you?
Josh |
Originally Posted by Bullitt390
(Post 14710391)
You're not using a Motorcraft filter with a NAPA oil filter cap are you?
Josh |
I decided to run another Air Test and command the IPR to see if I could hear air leaking from the oil filter housing to see if my HPOP is the culprit.
I hooked up the shop air with 150 psi and here the hiss as I guess I should. I hook up AutoEnginuity and turn the key on, I still hear the hiss from the oil fill tube, then I command the IPR to 100%, and I still here the hiss. From everything I've read/watched/listened to, that screams a bad IPR. This is the exact opposite thing that happened to me the other night. When I had shop air hooked up and turned the key, the hissing stopped and stayed stopped even when I commanded the IPR to 100% then when bringing the IPR to 0% it came back. Maybe when I took the IPR out and cleaned it really well with brake cleaner to change the screen it worked for a split second, just to spite me and keep me up at night thinking I'm one of the "rare" individuals to replace a HPOP in a 2005+ rig. Thoughts? |
Brake cleaner is pretty harsh and it can cause problems with the valve actuator electronics if it gets past the seals (and it is bad about degrading seals).
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