Off and On running/starting - Ford Powerstroke Diesel Forum
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Old 04-14-2012, 08:35 PM Rookie

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Off and On running/starting

I got a 96 F350, only mods is boost gauge, transmission temp gauge and tranny cooler.
I been having this problem for a few weeks and tried several things with no luck.
First thing I noticed is wait to start light is flickering real fast and hard to no start. Also relay number 2 is clicking when this happens. GPR was smoking so discounted all 4 wires. No help, changed out CPS started up and ran ok for 5 minutes then died again. Changed CPS again, and it would not start. went out next day and it started and idled for one hour as smooth as you ever want. I killed truck went back 2 hours later and no start. Changed CPS fuel filter. I got another IDM ( think that what it called big electrical unit on firewall on driver side) and no difference
Went back next day and it started up but ran rough and then died after few minutes of idling. I started remove electrical plugs to injectors, removed one and the wait to start light stayed on like it should and truck started but ran rough because of plug off, so plugged it back in and truck ran great, thought I found problem.
But couple hours later I tried to start it up same problem wait to start l;ight flickering and no start or very hard start and died after a few seconds of running. Un plugged plug no difference then tried all four one at a time a no change.
I have checked oil in HPOP, changed filter changed CPS couple times unplugged fuel heater but got it plugged in now, discounted all wires to GPR tried an new IPM, checked wiring harness plugs and looked ok to me. Batteries are good and it turns over fast. Also tried starting in neutral, no difference. Also switched relays out since #2 was clicking
Any ideas be appreciated
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Old 04-14-2012, 11:44 PM
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i'd have to say it sounds like burnt up injector connectors at the valve cover gasket under the valve cover.
what happens is the connector backs out causing resistance which causes them to burn up. the glow plug circuit also runs through it.
remove the valve cover from whichever side you disconnected.
once removed, disconnect the connectors which go from the injectors to the vc gasket connector. there will be 2 on each bank. they'll probably be crispy and burnt. if that is the problem, when you install the new ones, run a zip tie through the locking tabs to keep them from backing out again
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Old 04-14-2012, 11:51 PM
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P.S.....your in the wrong forum
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