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Discussion Starter · #1 ·
Last time my 2003 6.0 ran it started cutting out about1 mile from home on my way to
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work. Low power, little pedal response. It was almost a year ago and I am finally getting to work on my vehicle. I don't recall a lot of the details but as best I can remember it went like this.
I moved from the driveway and in front of my shop that was the last time it ran. I put it on my scanner and it didn't seem to be making enough oil pressure to start, I can't recall the number so I pulled the IPR and found it had a hole in the screen. Installed a new screen and turned it over. No start, removed the IPR and found what appeared to be some sort of elastomeric material on the screen.
That was last November sometime. This week I cleaned up the top of the engine and removed everything to get to the oil cooler and found a lot of material and part of some sort of black maybe silicone gasket. I see that the last person to replace the oil cooler Installed a Dorman part. I just want to know if anyone has seen this much material in the oil cooler sump. I don't understand how it even ran at all unless this was a very rapid failure and it happened all the sudden.
So, I have a few questions.

1- what is the likely source of this material

2- what do I do to flush the system to remove all of the contamination.

3- what parts do I need to be concerned with needing replaced. Obviously it would be simple to say to just replace everything in the high pressure oil system but that is not necessarily in my budget.

4- I have already purchased the parts for replacement of the oil cooler, ford parts. I purchased the truck with 188 k and it currently has 250 k . I had back flushed the oil cooler after I first purchased it and was planning on replacing it any way. Any other items that should go along with the oil cooler? The egr had failed on the prior owner and it was welded according to what I was told but looking at it it appears that it just has caps at either end.
 

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That mess is from a cheap oil cooler with the cheap soft goods (gaskets and o-rings) degrading.

I can't imagine that this mess didn't show up on the oil cooler. Anyway, the ENTIRE system feeding the HPOP needs to be cleaned. That means ALSO flushing the line from the oil cooler sump to the HPOP.

Since it is an 03, I would just plan on replacing the HPOP. IMO you will have yours fail at some point in the near future from starved suction flow, sludge, and maybe excessive heat. The only 03-04 HPOPs worth buying are the ones from DieselSite or CNCFab.

You may also need to clean out the high pressure system AFTER the HPOP - branch tubes and oil rails. Any of that crud that gets through to the injectors will ruin the injector spool valve operation.

BTW - a failed screen on the IPR valve will not cause problems, so simply replacing a broken IPR screen will not fix anything. When the screen is damaged, it was damaged by foreign materials (contamination) blocking the screen and the pressure will then push the materials through the screen. When this happens, the foreign materials can cause the IPR valve to stick and not operate correctly. This is what causes problems, the screen itself has nothing to do with it.....the IPR valve is just a dump valve.

I am surprised that you didn't get any oil into the coolant system!
 

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Discussion Starter · #3 ·
Thanks for your reply. I will look into the hpop that you recommended. I will be removing the from the housing tonight. I wrench a lot on just about anything and have a good customer base, but I am not very experienced with diesel engines. Your insight is greatly appreciated.
Do you have a preference for which hpop? It seems that the dieselsite unit has a better warranty. Thanks again!
 

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I have seen a lot of problems on many brands of the early (03-04) remanufactured HPOPs, even the OEM ones.

DieselSite HPOP would be my first choice, but the one from CNCFab is good also. I have only seen one thread about a bad DieselSite HPOP in a BUNCH of years and I watch all the 6.0L forums.

You may not need a new HPOP, but starving them for oil is hard on them and it is possible that the trash on the oil cooler sump screen could have caused significantly reduced oil flow. I hate going in to these engines that deep .... not because it is hard, but because my fingers don't work as well as they used to. Mainly the issue is the potential of dropping things into the engine. Also, I really like to nail all of the identified "weak areas" on these 6.0's and those early HPOPs are definitely a weak point.
 

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BTW - a failed screen on the IPR valve will not cause problems, so simply replacing a broken IPR screen will not fix anything. When the screen is damaged, it was damaged by foreign materials (contamination) blocking the screen and the pressure will then push the materials through the screen. When this happens, the foreign materials can cause the IPR valve to stick and not operate correctly. This is what causes problems, the screen itself has nothing to do with it.....the IPR valve is just a dump valve.
bismic, I agree with you on the IPR being a dump valve. However, I have had 3 known occasions that I have had a no start situation (low ICP Pressure at 84% IRP) and found the IPR screen to have been breached. Replaced the screen and instantly got 500+ psi and engine fired off.

Like this poster, on one occasion that foreign material was oil cooler gasket material from a recent oil cooler replacement. Owner was not very religious about keeping the workspace clean. I found the damaged IPR screen and with that little replacement, engine has been fine for 2 years.

I am not sure of that was a fluke, but I know the screen is to keep contaminants out of the valve, but it has something to do with holding a certain amount of oil in the system as well.

Just my expereince.


OP, you just asked about which HPOP. I have used 2 remanded units from Pensacola Diesel. They have been very good for me, very good service from this company and last I checked, a good price. They even wait 30 days to charge a core charge, o give you opportunity to get the core back to them without having to pay the fee.

I have been using them for Injectors and HPOPs for over 10 years.
 

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It is just coincidence then. The oil doesn't even flow through the IPR valve until the ICP pressure is higher than what is called for by the PCM. Replacing the screen will in no way assist the oil pressure (high pressure system) to increase.
 

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As far as Pensacola goes, I have to strongly disagree.

Lots of threads on various diesel forums about their injectors being bad out of the box.

Also, I just helped a guy in February that installed one of their HPOPs and it was bad out of the box. Took a while to nail that down, but a new HPOP solved his problem.

One example:

There are many more similar threads that will come up when searching.
 

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As far as Pensacola goes, I have to strongly disagree.

Lots of threads on various diesel forums about their injectors being bad out of the box.

Also, I just helped a guy in February that installed one of their HPOPs and it was bad out of the box. Took a while to nail that down, but a new HPOP solved his problem.

One example:

There are many more similar threads that will come up when searching.
Interesting.... I will say that I have had 2 occasions of a bad injector out of the box. That was on a set of 8. For me, not that big of a deal in that I have 4 trucks actively on the road, so I always have injectors. And, I have no customer service issues when calling for replacements. I usually get them next day, but I am in South Georgia and they in Pensacola Florida, so a quick shipping trip. I have also noticed that they have added an extra level of injectors (cheaper line) and you can tell the difference as the packaging is not as good. Not sure of the difference, but out of about 50+ injectors I have gotten from them, I have had 2 bad out of the box. One had a bad coil and the other the spool valve stuck. I have one other occasion where I replaced an entire set and 51 weeks later a coil went bad. They honored the one year warranty with no question.

As for the HPOP, I have used 3 rebuilt pump and no issues.

Certainly not disagreeing with your experience of of others that have posted, but I have had good luck and really good response so far.

Of course, other then buying OEM, is seems everyone has issues with injector suppliers. I have heard horror stories from Warren Injectors, Sinister, and about every other supplier. I have been told that no one is manufacturing NEW 6.0 injectors anymore and that all injectors are rebuilt or remanufactured, however you want to define the process. So, I am not sure who the absolute best and most reliable supplier actually is anymore.
 

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Thanks. I will check them out. I am not sure I have ever heard of them.
 
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