Need Help. No Start After New Injectors, Low ICP - Diesel Forum - TheDieselStop.com
'99 & up 7.3L Power Stroke Engine and Drivetrain Discussion of the '99 & up 7.3L Power Stroke diesel engine and drivetrain in the 1999-Up Super Duty trucks and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 7.3L Power Stroke engine.

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post #1 of 30 (permalink) Old 03-11-2018, 11:48 AM Thread Starter
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Need Help. No Start After New Injectors, Low ICP

Got my new injectors this past week and installed them yesterday.

Parts came in on Tues.

Full Force single shot 180/0
TS 6 position chip
Riff Raff FPX
Strictly Diesel Dieselsite HPX
Riff Raff Banjo Bolts


Installed the HPX on Wed. and fired up/checked for leaks. Ran fine.
Installed the FPX on Thurs. and fired up/checked for leaks. Ran fine.

Installed the injectors and chip yesterday and she cranks but no start.
Killed the batteries. Went and picked up 2 new ones.
Cranks and no start.

Hooked up ForScan.
Buzz test the injectors and they all fire and sound good.
ICP is only getting to about 200psi.
Cracked open the HPX fittings and bled the oil system by jumping the solenoid, key off.
Good oil flow from the HPX. Tightened everything back up.


Unplugged the ICP sensor. ForScan shows over 2100psi ICP while cranking.
Checked oil level. Good
Checked oil level in HPOP res. Good.
Checked fuel bowl. Clean fuel, no oil mixing.


No fuel pressure gauge yet, Ordered.


At a loss here.
Thinking of removing the chip and trying to start...


I really hope I don't have to open her back up and pull injectors...

"Slow White"
Early 99 7.3, 11/98 build, 6spd, X-cab XLT DRW 2WD, 145k and counting
Full Force 180/0 single shot injectors, TS 6 position chip
Riff Raff FRX, Riff Raff Banjos, Strictly Diesel HPX
4" DP and straight pipe exhaust, 6637 air filter
Hutch mod, CCV mod, coolant filter
South Bend 1944-60K-HD clutch

Last edited by roozterdvx; 03-11-2018 at 04:23 PM.
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post #2 of 30 (permalink) Old 03-11-2018, 12:13 PM Thread Starter
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Pulled the chip...

No start.
ICP at 195psi

Pulled the ICP connector.
ICP shows 2100+psi

"Slow White"
Early 99 7.3, 11/98 build, 6spd, X-cab XLT DRW 2WD, 145k and counting
Full Force 180/0 single shot injectors, TS 6 position chip
Riff Raff FRX, Riff Raff Banjos, Strictly Diesel HPX
4" DP and straight pipe exhaust, 6637 air filter
Hutch mod, CCV mod, coolant filter
South Bend 1944-60K-HD clutch
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post #3 of 30 (permalink) Old 03-11-2018, 12:17 PM
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It can take a LOT of cranking to get all the air out of the system. As you know, until you get above 500 psi, the computer won't fire the injectors. The trick Kevin came up with, and most of us use, is to crank the engine with the glow plugs still out until you hear the HPOP load up. That saves the batteries. After switching to that method, I've never had one not fire right up right away when I button everything back up.

If you suspect you've done something to prevent oil pressure from building, lay a straight edge across the injector solenoids. If you have one that didn't seat, you'll have to pull just that one. If they all seem to be at the same height, you're going to have to keep cranking until that pressure builds to 500+ psi.

Don't forget to double check all the connectors. The only one I couldn't get to fire up was the one I had left the main harness connector disconnected.

2003 F-250 XLT Crew Cab 7.3L, Chrome BigTex Grille Guard, Quad pillar - 3 ISSPRO gauges (trans, pyro, boost) and DP-Tuner F6; Roush fuel pressure / temperature / oil pressure gauges, Ford Severe Duty AIS, 31 row 6.0 transmission cooler, ScanGauge II, Marinco mod, Walker BTM, Full Force Stage 1 injectors

IF MY BODY IS EVER FOUND ON A JOGGING TRAIL JUST KNOW THAT I WAS MURDERED SOMEWHERE ELSE AND DUMPED THERE
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post #4 of 30 (permalink) Old 03-11-2018, 12:39 PM Thread Starter
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Put the chip back in.
Just checked the main connector on driver side valve cover.

Cranked and no change.

Going to pull the valve covers... ugh.

"Slow White"
Early 99 7.3, 11/98 build, 6spd, X-cab XLT DRW 2WD, 145k and counting
Full Force 180/0 single shot injectors, TS 6 position chip
Riff Raff FRX, Riff Raff Banjos, Strictly Diesel HPX
4" DP and straight pipe exhaust, 6637 air filter
Hutch mod, CCV mod, coolant filter
South Bend 1944-60K-HD clutch
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post #5 of 30 (permalink) Old 03-11-2018, 12:46 PM
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How much total cranking time have you done? The "standard" is up to 20 cranking cycles of 30 seconds each with a several minute cool down between each cycle. I'd be tempted to disable the glow plugs and give it a very light shot of ether before pulling it apart again. It could be your starter isn't up to the task of priming the system. Do NOT use ether with the glow plug system intact.

2003 F-250 XLT Crew Cab 7.3L, Chrome BigTex Grille Guard, Quad pillar - 3 ISSPRO gauges (trans, pyro, boost) and DP-Tuner F6; Roush fuel pressure / temperature / oil pressure gauges, Ford Severe Duty AIS, 31 row 6.0 transmission cooler, ScanGauge II, Marinco mod, Walker BTM, Full Force Stage 1 injectors

IF MY BODY IS EVER FOUND ON A JOGGING TRAIL JUST KNOW THAT I WAS MURDERED SOMEWHERE ELSE AND DUMPED THERE
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post #6 of 30 (permalink) Old 03-11-2018, 02:09 PM Thread Starter
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Just pulled the valve covers.
Straight edge across the injector solenoids on both side is good. No noticeable gaps.

Disconnected and pulled the glow plugs out.
Cranked for about 20 seconds and letting the starter cool down.

Going to give it a few more cycles like this.

How can I tell if the HPOP is loaded up?
Or is there an approximate number of cycles and just button her back up?

"Slow White"
Early 99 7.3, 11/98 build, 6spd, X-cab XLT DRW 2WD, 145k and counting
Full Force 180/0 single shot injectors, TS 6 position chip
Riff Raff FRX, Riff Raff Banjos, Strictly Diesel HPX
4" DP and straight pipe exhaust, 6637 air filter
Hutch mod, CCV mod, coolant filter
South Bend 1944-60K-HD clutch
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post #7 of 30 (permalink) Old 03-11-2018, 03:35 PM Thread Starter
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Got her all buttoned back up.
Still cranking...

ICP still says 195psi


When the ICP sensor is disconnected and ForScan is showing 2100+ psi for ICP pressure, shouldn't it try to fire the injectors?

"Slow White"
Early 99 7.3, 11/98 build, 6spd, X-cab XLT DRW 2WD, 145k and counting
Full Force 180/0 single shot injectors, TS 6 position chip
Riff Raff FRX, Riff Raff Banjos, Strictly Diesel HPX
4" DP and straight pipe exhaust, 6637 air filter
Hutch mod, CCV mod, coolant filter
South Bend 1944-60K-HD clutch

Last edited by roozterdvx; 03-11-2018 at 04:24 PM.
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post #8 of 30 (permalink) Old 03-11-2018, 08:24 PM
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It should give the electrical signal to fire the injectors, but if there is really only 195 psi, there won't be enough pressure to inject the fuel. While cranking with the glow plugs out, you will here the tone of the starter change as the load of the HPOP is added once it pushes the air out and is actually building pressure. Check your IPR connector - might have knocked it loose.

2003 F-250 XLT Crew Cab 7.3L, Chrome BigTex Grille Guard, Quad pillar - 3 ISSPRO gauges (trans, pyro, boost) and DP-Tuner F6; Roush fuel pressure / temperature / oil pressure gauges, Ford Severe Duty AIS, 31 row 6.0 transmission cooler, ScanGauge II, Marinco mod, Walker BTM, Full Force Stage 1 injectors

IF MY BODY IS EVER FOUND ON A JOGGING TRAIL JUST KNOW THAT I WAS MURDERED SOMEWHERE ELSE AND DUMPED THERE
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post #9 of 30 (permalink) Old 03-11-2018, 09:39 PM Thread Starter
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I did check the IPR connector and the rubber seal isn't in the best of shape but it's plugged in good.

Picking up another IPR tomorrow from a buddy after work. Believed to be good.

I'm going to swap out the solenoids first and see if ICP pressure comes up.
Then I'll try swapping the valve and check pressure again.

"Slow White"
Early 99 7.3, 11/98 build, 6spd, X-cab XLT DRW 2WD, 145k and counting
Full Force 180/0 single shot injectors, TS 6 position chip
Riff Raff FRX, Riff Raff Banjos, Strictly Diesel HPX
4" DP and straight pipe exhaust, 6637 air filter
Hutch mod, CCV mod, coolant filter
South Bend 1944-60K-HD clutch

Last edited by roozterdvx; 03-11-2018 at 09:43 PM.
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post #10 of 30 (permalink) Old 03-12-2018, 05:14 PM Thread Starter
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Swapped out the IPR.
Still only 200psi ICP pressure on ForScan.

"Slow White"
Early 99 7.3, 11/98 build, 6spd, X-cab XLT DRW 2WD, 145k and counting
Full Force 180/0 single shot injectors, TS 6 position chip
Riff Raff FRX, Riff Raff Banjos, Strictly Diesel HPX
4" DP and straight pipe exhaust, 6637 air filter
Hutch mod, CCV mod, coolant filter
South Bend 1944-60K-HD clutch
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post #11 of 30 (permalink) Old 03-12-2018, 05:36 PM Thread Starter
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Called in to Full Force.
Waiting for a call back...

"Slow White"
Early 99 7.3, 11/98 build, 6spd, X-cab XLT DRW 2WD, 145k and counting
Full Force 180/0 single shot injectors, TS 6 position chip
Riff Raff FRX, Riff Raff Banjos, Strictly Diesel HPX
4" DP and straight pipe exhaust, 6637 air filter
Hutch mod, CCV mod, coolant filter
South Bend 1944-60K-HD clutch
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post #12 of 30 (permalink) Old 03-13-2018, 11:55 AM Thread Starter
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Full Force called me back.
They say next logical step is to check the injectors for oil leaks or unrestricted flow though.

Going to pull the valve covers off again after work today...
Disconnect the injectors and crank her over to look for oil out of the injectors.

If I understand right...
If a top o-ring is damaged, oil should come out under the hold down clamp.
If the middle o-ring is damaged, oil would mix with the fuel and return to the bowl. (Bowl was checked previously and clean. No oil just clean green fuel)
If an injector poppet valve is stuck, oil should flow out of the deflector spout.

"Slow White"
Early 99 7.3, 11/98 build, 6spd, X-cab XLT DRW 2WD, 145k and counting
Full Force 180/0 single shot injectors, TS 6 position chip
Riff Raff FRX, Riff Raff Banjos, Strictly Diesel HPX
4" DP and straight pipe exhaust, 6637 air filter
Hutch mod, CCV mod, coolant filter
South Bend 1944-60K-HD clutch
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post #13 of 30 (permalink) Old 03-13-2018, 02:09 PM
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Well - look at it this way - you're going to be the site expert on pulling valve covers...

2003 F-250 XLT Crew Cab 7.3L, Chrome BigTex Grille Guard, Quad pillar - 3 ISSPRO gauges (trans, pyro, boost) and DP-Tuner F6; Roush fuel pressure / temperature / oil pressure gauges, Ford Severe Duty AIS, 31 row 6.0 transmission cooler, ScanGauge II, Marinco mod, Walker BTM, Full Force Stage 1 injectors

IF MY BODY IS EVER FOUND ON A JOGGING TRAIL JUST KNOW THAT I WAS MURDERED SOMEWHERE ELSE AND DUMPED THERE
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post #14 of 30 (permalink) Old 03-14-2018, 08:27 AM Thread Starter
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Quote:
Originally Posted by RT View Post
Well - look at it this way - you're going to be the site expert on pulling valve covers...
No kidding...lol


I got home from work and had everything stripped down including glow plugs out in just under 1 hour.


My buddy came over to help with cranking so I could look for leaks and while waiting for him I cleaned around the injectors and noticed something different about 1 injector.
The oil discharge hole that should line up with the deflector spout, doesn't...
Basically, if you hold an injector upright with the electrical connector facing you, the oil hole should be to the right of center. This 1 has the hole to the left of center.


Now I'm thinking, this is it! I got a FUBAR injector!
Called Full Force and sent them a picture. They said their best guess is that that poppet plate was drilled wrong during manufacturing. It is impossible to assemble that plate upside down onto the injector body as the 4 bolt holes are counter bored to recess the bolts.
I pulled a coil off 1 of my old injectors and confirmed as I didn't want to believe it.


Well, cranked her over looking for oil leakage or oil dumping from a deflector spout. Found none.
Cranked for 20-30 second intervals with cool down periods for the starter and it was starting to smell a little. Put a fan underneath it to help keep it cool but it looks like I'll be replacing that soon.


Going to call Full Force back again today to discuss "our" next step.
Also trying to find a hydraulic shop so I can piece together some fitting to deadhead test the HPOP.

"Slow White"
Early 99 7.3, 11/98 build, 6spd, X-cab XLT DRW 2WD, 145k and counting
Full Force 180/0 single shot injectors, TS 6 position chip
Riff Raff FRX, Riff Raff Banjos, Strictly Diesel HPX
4" DP and straight pipe exhaust, 6637 air filter
Hutch mod, CCV mod, coolant filter
South Bend 1944-60K-HD clutch

Last edited by roozterdvx; 03-14-2018 at 08:51 AM.
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post #15 of 30 (permalink) Old 03-14-2018, 08:52 AM Thread Starter
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Pic of injector with deflector spout
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"Slow White"
Early 99 7.3, 11/98 build, 6spd, X-cab XLT DRW 2WD, 145k and counting
Full Force 180/0 single shot injectors, TS 6 position chip
Riff Raff FRX, Riff Raff Banjos, Strictly Diesel HPX
4" DP and straight pipe exhaust, 6637 air filter
Hutch mod, CCV mod, coolant filter
South Bend 1944-60K-HD clutch
roozterdvx is offline  
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