[John in OkieLand]

Thank you for that PDF document.

 

[bhnightraith]

I actually wrote it out by hand drawings included, so that i didnt lose it. but glad you have it for others to use as well.

 

[bhnightraith]

i tested the wiring harness. Everythinng tested between 2.8 ohms and 3.2 ohms, and there were no shorts across power or ground.....i have no idea what to test....everything is showing like it should fire.

 

[bhnightraith]

I pulled a reading at the fuel bowl and found that there was no fuel pressure at the shrader valve, or at least hardly any. So I tried turning over the engine with the fuel filter out, and no fuel was coming from the fuel pump. So I'm pulling the fuel pump. I picked up a electric fuel pump, and I'm going to see if I can figure out a way to wire it in so that itll work as needed. Finally picked up a FORscan tool freom amazon, and I came back with the following trouble codes P0562, P1661, P0603, P0344, P1212, P0237, P1211 from the KOEO Output State Self Test. and then KOEO Injector Electrical Self Test resulted in the following trouble codes P1293, P1294. If anyone has an idea of where i can find a good example of how to wire in the fuel pump, id appreciate it.

 

[bugman]

I doubt that the electric pump that you got is going to work.

Our fuel pumps are a two stage fuel pump. It draws from the fuel tank on the low pressure side and sends the fuel to the filter housing. It then draws the fuel from the filter housing back to the pump and then to the injectors on the high pressure side and back to the FPR and then back to the tanks.

If the electric fuel pump supplies high pressure to the filter housing you are going to have fuel all over the place since the filter housing is not designed for high pressure. If you do want to go to a electric pump you need to change out the filter housing to one that will sustain the pressure, that among other parts that you will need.

 

[Bob7.3]

I pulled a reading at the fuel bowl and found that there was no fuel pressure at the shrader valve, or at least hardly any.

Interesting. Did you determine what changed from a few days ago, post 14?

"Well, I have over 25psi at the shrader valve on the side of the fuel bowl, so thats showing the fuel pump is doing its job.....what else could be wrong i am stumped!"​

If it's working intermittently, that would tend toward a diagnosis of a bad electrical connection. Might still be the pump on its way out, but maybe not. Hard-wire to find out.

 

[bhnightraith]

I got the truck to start with a small shot of starting fluid into the air filter. It kept running for a little while, like 5 minutes, but then went back to wouldn't start. It's weird that it kept running that long? After that i wired in the electric fuel pump and the bowl filled with fuel, but it wouldn't actually fire....I'm wondering if the fuel pump is just toast. So I took a code test and came back with P1293 P1294, so open bank of both sides of injectors? Does that mean wiring or fuel is open? No pressure in the fuel on each side or open wiring on each side? This is SO frustrating I've been working on this for weeks and have got to get back to work!

 

[bhnightraith]

I replaced the fuel pump and my new Forscan tool ncame. I still have no fire, but Here is whgat the tool is giving me for readings. ICPV started at 14 then jumped to 500, then right back down to 17.5.
rpms were around 170-200, icp reding sat at 2400, IPR sat at 35%. I also have a fuel bank open on both 1 &2 fuel banks. does that mean I dont have fuel after jiust replacionbg the pump?

 

[bhnightraith]

I did a few tests and here nare the results
KO(OK) [14:58:53.190] KOEO Injector Electrical Self Test has been started
(WARN) [14:59:06.364] Test completed, found DTCs: P1293, P1294
(OK) [14:59:29.631] KOEO Output State Self Test has been started
(WARN) [15:01:34.933] Test completed, found DTCs: P0562, P1661, P1280, P0603, P0344, P1212, P0237, P1211
(ERR) [15:02:53.032] KOER Switch Self Test has been cancelled by operator
(ERR) [15:03:06.845] KOER Cylinder Contribution Self Test has been cancelled by operator
(OK) [15:03:19.172] Key On Engine Off On Demand Self-Test has been started
(WARN) [15:03:22.258] Test completed, found DTCs: P0475, P1293, P1294
(OK) [15:03:38.200] Read system monitor status has been started
(WARN) [15:03:38.224] Malfunction Indicator Lamp (MIL) Status: On
(WARN) [15:03:38.225] Misfire monitoring: Not supported
(WARN) [15:03:38.225] Fuel system monitoring: Not supported
(WARN) [15:03:38.226] Comprehensive component monitoring: Not supported
(WARN) [15:03:38.227] NMHC Catalyst monitoring: Not supported
(WARN) [15:03:38.228] NOX/SCR Catalyst monitoring: Not supported
(WARN) [15:03:38.228] Boost Pressure monitoring: Not supported
(WARN) [15:03:38.229] Exhaust Gas Sensor monitoring: Not supported
(WARN) [15:03:38.230] PM filter monitoring: Not supported
(WARN) [15:03:38.231] EGR and/or VVT System monitoring: Not supported
(OK) [15:03:45.468] Test completed successfully, no errors found
(OK) [15:03:52.910] Mode 6 - Test Results for Specific Monitored Systems has been started
(ERR) [15:03:53.564] Test completed, malfunction detected

Looking at my data as i try to start,
IPR% jumps to 54.9% and stays there as i crank
ICPV psi bounces really fast between 48 and 370 or so?
ICP psi jumps up and stays around 350-370 and stays until after a bit it jumps to 2400
Engine RPM's are right around 170+/-5

Also, when the ICP reading jumps to 2400, the IPR% drops to35.55 and stays there.
The fuel banks 1 and 2 read a constant -100

I hope someone can PLEASE make heads or tails freom this info????

 

[bhnightraith]

Also, for some reason it says I have like 150 trouble codes but wont show them to me, the DTC screen says no DTC's found, and one of the DTC's was a memory lack of power, or loss of power to memory module.,.....Is that pointing toward a bad computer in the truck?

 

[bhnightraith]

Ok guys everyone said that they needed me to read trouble codes, so I we3nt out and picked up the forscan tool, now I cant seem to get anyone to help me decipher the results....please come back you guys were helping at least eliminate things that it wasnt.

 

[bhnightraith]

I pulled the IDM yesterday and pulled it apart to check and see if anything was burnt. It appeared to be ok, wioth no brown or discolored parts and all the caps seemed intact. There was no "burnt popcorn" smell. So that wasnt the issue. before I put it back in I'm going to again check the ohms/test the wiring harness through the idm plug.

 

[Bob7.3]

From what I hear...

Haha, ok, sorry, that's all I got. Guessing the mods and changing situation is keeping the gurus away. IDK, maybe do a quick update of major points to reinvigorate the thread?

 

[bhnightraith]

Alright, I just want to go through and get everything I've done down and keep the page up to date. This is 95 ford 7.3 turbo diesel direct injected. The only mod was the back pressure gate is no longer hooked up, and forced open at all times. I rebuilt the injectors and the turbo trying to get rid of alot of smoke while driving issue. But it didn't seem to make a difference. I've come to think that the problem was that the ipr valve was actually staying open to about 50% or more while driving, forcing nearly 4000psi to the injectors. The other day I had the vehicle running but (from what I believe)the vehicle kept throwing a CEL and going into limp mode because of the overly high pressure. So I tried rebuilding the ipr, but I'm fairly sure it's toast because now it won't fire. I purchased a new ipr and waiting for it to get here on Monday. I was going to have my injectors tested but it would end up running me over 400$ at the local shop so I'll save that as a last resort.

 

[bhnightraith]

I replaced the IRP VALVE TODAY. The truck fired up fairly easily, but to he injectors were hitting really hard! I hooked up the forscan tool and I m getting readings of 5,000-10,000kPa! The ipr started at 21% and leveled out around 17%, jumping to 27% with some gas pedal.......is it a bad icp?

 

[Patrick Feeley]

That's about 750 psi to approximately 1500 psi, so that seems ok to me. There might be air in the system still. Cheers!

 

[Jcart]

As a suggestion I’d unhook your batteries totally from the truck after clearing all the DTC’s first. Not used Forscan, but have used AutoEnginuity a bunch. Once truck has sat for 15 minutes hook back up and check for codes… shouldn’t be any. Now try to fire truck up and any DTCs showing will be current. What HPOP are you using, remember that you need a minimum of 500 psi High Pressure Oil to fire injectors.