HELP!! 96 7.3 won't start - Ford Powerstroke Diesel Forum
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post #1 of 5 Old 11-10-2012, 01:37 PM Thread Starter
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HELP!! 96 7.3 won't start

I changed all the hoses on the fuel filter housing to the fuel lift pump today , and had the filter housing completely off the truck. While in there i noticed the wiring coming off the housing (red and white wire) were melted together and frayed at the connector. I need to know what these wires are for?? It looks like they plug into the back of the hpop?? Also I went to start my truck and it just cranks over, the tach moves up to 1000 rpms or so , so I don't think its the cps. The #22 fuse isn't blown either. I can spray starting fluid into the intake and it attempts to start but still no go. PLEASE help this is my daily driver and i need it running!! I am new to diesels and don't know anything about them. Also the filter housing is about 3/4 way full .
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post #2 of 5 Old 11-10-2012, 01:53 PM
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First do not use any combustable fluid with the GPR still working. The IPR (attached to the HPOP) is red on one side and yellow w/red stripe on the other side. If these wires aren't in order you won't build enough hydraulic pressure to fire an injector. Cut out the bad connector and wiring and hit a napa. They stock most connectors though the wire colors are usually wrong (not that it matters right now. SOLDER the new wires in.

+ Matt - Star Tiger +
-Bean's: 160/100 (FF Injectors), 2/ 6-POS chips (TW & Beans tunes), Overboost controller, E-Fuel
-BANKs: downpipe, full exhaust, gauges, test pipes, intercooler
-Irate: T-4 kit, IC pipes, 3" Replacement Plenums, BASB Turbo
-Mag-Hytec trans. and pumpkin covers
-6637, CCV, IDM, 6.0 Fan, 49-Federal PCM swap, MAP line Mod
-370 Amp alt., 40k trans cooler, SRP1.1
-twin on-board air w/ 10 gal. tank

Re-pinning '97 Cali PCM to Federal
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post #3 of 5 Old 11-10-2012, 04:47 PM
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Your wiring, though melted, sounds good enought to start the truck. Since all you've done is install new hoses to the fuel bowl you may just need to get all the air out. If possible have someone else crank the truck while you hold the Schroeder valve open at the back of the bowl. Get out all the air. Next crack the two lines from the front of the heads that connect to the brown and crank in spurts till only fuel comes from those lines. Now you have removed as much air from the fuel as possible. If the motor starts while purging shut it down till you close all the open lines. Check fuse 8 also.

+ Matt - Star Tiger +
-Bean's: 160/100 (FF Injectors), 2/ 6-POS chips (TW & Beans tunes), Overboost controller, E-Fuel
-BANKs: downpipe, full exhaust, gauges, test pipes, intercooler
-Irate: T-4 kit, IC pipes, 3" Replacement Plenums, BASB Turbo
-Mag-Hytec trans. and pumpkin covers
-6637, CCV, IDM, 6.0 Fan, 49-Federal PCM swap, MAP line Mod
-370 Amp alt., 40k trans cooler, SRP1.1
-twin on-board air w/ 10 gal. tank

Re-pinning '97 Cali PCM to Federal
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post #4 of 5 Old 11-10-2012, 05:24 PM Thread Starter
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Thanks!

Thanks BigFuel for the advice i rewired the IPR factory connection and it started first try. Its nice to have people out there who are still willing to help.!!
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post #5 of 5 Old 11-11-2012, 07:34 AM
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Thank you for the kind words. There are a lot of us, I just got to you first.

+ Matt - Star Tiger +
-Bean's: 160/100 (FF Injectors), 2/ 6-POS chips (TW & Beans tunes), Overboost controller, E-Fuel
-BANKs: downpipe, full exhaust, gauges, test pipes, intercooler
-Irate: T-4 kit, IC pipes, 3" Replacement Plenums, BASB Turbo
-Mag-Hytec trans. and pumpkin covers
-6637, CCV, IDM, 6.0 Fan, 49-Federal PCM swap, MAP line Mod
-370 Amp alt., 40k trans cooler, SRP1.1
-twin on-board air w/ 10 gal. tank

Re-pinning '97 Cali PCM to Federal
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