97 7.3 injector problems - Ford Powerstroke Diesel Forum
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Old 05-29-2010, 03:04 PM
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97 7.3 injector problems

Hello, Thursday i pulled my injectors on my 7.3 and did a stage 1 diy kit. This was my second time doing a rebuild kit( i helped my buddy do a stage 1 kit in his truck with great success). So i pulled my injectors disassembled, and put individual injector parts in their own bags to keep the parts separate. I had the intensifier pistons machined by a reputable machine shop, and they are all within a half a thousandth of each other as per the instructions. I reassembled the injectors and am about 99 percent sure they where reassembled correctly. I reinstalled the injectors without any problems, new glow plugs, and put the valve covers back on. I cranked the engine 30 seconds at a time until it fired, it ran rough for a little while, and then smoothed out. It sounds like it still has a miss on at least 1 cylinder. I let it idle for around a half hour and turned it off. I went to re-fire it and it took at least 10 seconds of cranking for it to finally fire, it ran rough and smoothed out once again. i took it through out the rpm range and let it idle, still sounding like its missing on a few cylinders. I took it for a short test drive and right before turning back in the driveway the truck stalled. I tried starting it about 30 seconds later and it wouldn't start. I waited about 5 minutes, tried starting it again, it fired after about 20 seconds of cranking. I have checked, and double checked everything that comes to mind and have no ideas. Today i went to start it it started after about 10 seconds of cranking, and put it on high idle after about 5 minutes of idling after about a minute on high idle it sounded like it was going to stall so i quickly switched to a normal idle setting, it idled back to its normal idle rpm then stalled shortly after. It sounds like a lack of fuel issue to me but i'm not sure where to start. i checked my fuel pressure gauge and it is right around 80 psi. I put the truck on a scanner, ran a buzz test and it passes, tried to do a cylinder contribution test however it wouldn't let me because it said my oil temp sensor was bad, i replaced my sensor with a sensor from my buddies truck cleared the codes, and tried again but again it said the sensor was bad. I have no idea what to try next, and need the truck running grade A ASAP. any help would be greatly greatly appreciated. Thanks.
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Old 05-30-2010, 07:50 AM
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did you add oil back to the hpop resevoir?
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Old 05-30-2010, 03:13 PM
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I did not add any oil to the resevoir i was told that the injection system was self bleeding. i just today pulled the valve covers, started the truck and one at a time unplugged the injectors. 2 of the injectors made no difference in the running of the truck, so i assumed they weren't right. I pulled them and disassembled them. i installed some .001 shims under the armature to bring them back into the tolerances. I reinstalled the injectors and the idle problem improved and seemed to have smoothed out the miss. i let the truck idle for a while and it seemed to be running better. idling smoother and revving fine. i decided to take it out on the road, on the way down my driveway it was running good. As soon as i took it out on the road i gave it about quarter throttle and i knew it was doing the same thing as before. I pulled in the first driveway and it stalled out. I let it sit for about a minute and started cranking it. I cranked for about 30 seconds and it fired a couple pops, i let it sit a little longer and cranked again, this time it fired and stayed running after about 20 seconds. i was able to get it to my driveway before it stalled. i have no idea what to do with the darn thing and would love to have it running good by tuesday. Thanks for any help.
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Old 06-02-2010, 01:57 PM
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I just had a similar stalling problem / no start. I checked the oil level in the HPOP reservoir and it was pretty much empty. I refilled the reservoir with fresh oil and it started right back up. I believe that when you remove the injectors, you probably loose about 2-3 quarts of oil. Anyone please chime in if I am wrong in this thinking! But, I do know it's any easy check. Plus make sure your engine oil level is up. I know this is simple, but sometimes we look at the harder things instead of easier. I still do it, and I'm 40.

Best of luck!

Hammy
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Old 06-02-2010, 05:43 PM
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injector problem

Problem solved! When i installed the injectors i didn't have a torque wrench so i did the old "snug and a little" method i pulled the valve covers and tightened each of the injector hold down bolts about a quarter to a half of a turn. The truck is now running good.
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