Low ICP after Injector removal/replacement - Ford Powerstroke Diesel Forum
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Old 01-19-2013, 06:55 AM
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Low ICP after Injector removal/replacement

Back Again.

I had the lowest O-Ring (the white one) on my #4 injector to blow. After replacing the O-rings/Copper on the injector and cleaning the injector and bore hole, we replaced the injector and now she wont start.

I'm only getting 299 psi on my ICP with my livewire.

We replaced the standpipe oil tube (crankcase to head) when we reinstalled the HPOP rail but we didn't replace the dummy tube because we didn't remove it.

She would crank before this happened, even with the injector blowing fuel into the cylinder.

Question: Does anyone know if it is possible to screw up the installation of this standpipe tube? i.e. can the plastic back-up ring not compress properly? The whole standpipe was dipped in a gallon jug of T6 Rotella before we installed her. If not, what could be the problem with my low HPOP?

Also, Is it necessary to replace the internal o-ring at the top of the injector (where the HPOP Rail nipple slides into the injector) when removing/reinstalling the oil rail? We didn't but the injectors are fresh off a rebuild from Warren Diesel so I didn't think that was necessary.
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Old 01-19-2013, 07:32 AM
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The simple way to figure it out is to pull the valve cover on the side you worked on and removed the ICP sensor and supply shop air to the system. This will show you where the leak is. You should close the IPR as well but with a leak that big you should be able to find it. The dummy plugs have been updated as well I would get one and put it in if you open the valve cover again.
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Old 01-19-2013, 07:58 AM
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Thanks Toren302. Great idea. The updated dummy plugs were installed when the injectors were rebuilt. Is there any need to replace them if they weren't removed from the HPOP rail?
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Old 01-19-2013, 08:19 AM
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You may have damaged the o-ring in top of a injector when reseating the oil rail back on.
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Old 07-14-2013, 05:48 PM
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Update on this, just because I hate when people don't provide any explanation of what was really wrong.

The problem was the o-ring that connects the high pressure oil rail to the high pressure oil pump at the rear of the motor. We pulled the motor to replace this o-ring and while it was out, we went ahead and replaced all of the injector sleeves too.

She's been making me money ever since.
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Old 07-14-2013, 05:51 PM
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Good to hear...Thanks for posting the solution as well.
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