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Old 02-06-2012, 03:01 PM
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start-up after engine rebuild

I am attempting to get the truck fired up after a fairly complete engine teardown, cleanup, and rebuild. I've done some searching and have learned it will take some cranking time to purge the air from the HP oil system. I have about 10-12 cranking cycles complete (10-15sec crank time, 10 min starter cool down) but have no indication the truck is about to fire. How much more cranking is typical at this point?

I did not remove or dissassemble the HPOP, reservoir, or IPR from the engine but the oil did get fairly well drained from all of the block rotating in order to install bearings, welded oil jets, rings/pistons, hone, etc.

Also I have had the AE connected to check things out: injector buzz test good, volts while cranking have been above 11, rpm about 140, ICP = 0psi, IPR % = 14 KOEO (off the top of my head I don't remember what happend while cranking). How long should it take before I start seeing ICP get above 0psi? Is there a quicker way to prime/purge the HP oil system? Maybe pull a galley plug in each head and at least fill the HP oil rail with oil?
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Old 02-06-2012, 06:58 PM
RV1 RV1 is offline
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The situation gets more dire After another fruitless evening of starting attempts here is what I have found:

I verified the HP oil system is getting oil by cracking a galley plug and oil seeped out, the HPOP reservoir is full of oil and stays full (remember to re-install the allen head plug before cranking the engine or everything near the front gets an oil bath --ask me how I know ) IPR duty cycle reads 14.84% at KOEO, climbs to about 64% during cranking and stays there for the duration of cranking. ICP sensor reads 0psi with ignition on and during cranking (after about 20+ cranking cycles I think I should see some kind of pressure here), I unplugged the sensor and AE says ICP is 2338psi during cranking. Does this sound like a possible bad ICP sensor?

Also did some more checks and came back with P0605 - Internal Control Module Read Only Memory (ROM) Error, I don't think I have ever got that code before but I did install a DP tuner during this adventure. Is it normal to see that with a chip installed or is it bad news?

I also got a code for the EBPV solenoid which I am not surprised about since that connector kind-of got smashed during engine removal or install and I was hoping it would still work and save me about $110. Apparently it doesn't, would that have anything to do with these start-up issues?
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Old 02-10-2012, 10:38 AM
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Just to add some closure to this thread, the problem was missing HP oil galley plugs. Two of them inside the valve cover near the top of the head between first two injectors and last two injectors. The first rebuilt head that I installed had the plugs already installed so I didn't even think about it on the second head. After I installed the plugs, connected things back up and prefilled the HP oil galley it fired up in about 5 seconds.

Then I went to take it for the 40 mile drive to work all the air out of the system and the new Southbend clutch I installed would not release. It turns out that you have to use the Southbend solid flywheel with their clutch I guess. It doesn't work with a Valeo solid flywheel. So I changed back to the original Valeo clutch and am back on the road. FYI one person can change a clutch in a 4wd truck with two transmission jacks and air tools in less than 4 hours if you get the wife to help push, shove, wiggle, rotate, align, smash fingers, cuss, push some more for 20 minutes of getting the input shaft back through the friction disk splines and pilot bushing.
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