Starting issue after rebuild - Ford Powerstroke Diesel Forum
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Old 07-02-2013, 12:04 PM
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Starting issue after rebuild

I rebuilt an early 99 7.3 powerstroke, Stage 2 unlimited diesel injectors, deliminator 66 turbo, and a ts 6 position programmed by Gearhead. When I start the truck up there is a lot of white smoke and it runs very rough and dies. I checked the fuel pressure and it's at 20 psi. I took the return line off and with the pump running nothing came out. I put a new fuel pump on and now there is flow in the return but still only gets 20 psi and runs the same. The fuel pressure is supposed to be around 50 psi correct? Is the low fuel pressure the problem? Or is there possibly a different problem?
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Old 07-03-2013, 10:38 AM
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Does anyone have any ideas?
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Old 07-03-2013, 05:20 PM
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Did you prime the injectors with oil? Prior to plugging in the injectors you should have turned the engine over for 45-60 seconds to fill the oil rails and injectors with oil and fuel. If not you will get a lot of white smoke, it will run rough for a while and cut out a little. You can also damage the injectors if you did not prime them correctly as the fuel lubricates the injectors. Do you a way to monitor high pressure oil pressure? It should be 500psi and fuel pressure should be 55-60. It will run at a lower fuel pressure but lack power a full throttle.
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Old 07-03-2013, 05:25 PM
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check fuel tank restriction , might be clogged in tank and with the larger injectors cant keep up , really depends on how much smoke your getting to make my mind up on what you might have goin on
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Old 07-04-2013, 05:51 AM
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I filled the hpop resivor and cranked the motor over until there was pressure on the gauge before I plugged the injectors in. I got the fuel pressure at 50psi now. I holds 50 constantly while its running too. I will check the high oil pressure. It really acts like is fighting high timing. Like running the single shot injectors at the stock timing like if the chip is not plugged in properly. I took the pcm apart twice and cleaned it very well I'm certain the chip connection is not the issue. Has anyone ever damaged the pcm installing the chip?
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Old 07-07-2013, 02:01 PM
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I hooked a scan tool up to it today. It wasn't throwing any codes, the injector buzz test checked out ok, put a new cam position sensor in, hpop psi is good and it still doesn't work. It is blowing fuel out the exhaust. Maybe a flooding cylinder? I am going to pull the injectors and inspect the washers, o rings and tips. Is there anything else I should look for?
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Old 07-07-2013, 02:58 PM
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500psi in hpop is what needed to fire the injectors. If its starting, then you have enough psi. Once running and the higher rpm, you should see higher psi.

Might wanna remove the vc's again, and lay a straight-edge across the injectors, making sure alls seated correctly. You could have damaged a copper washer and/or not have one in on one injector...
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Old 07-07-2013, 04:09 PM
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Alright. The scanner said the oil pressure was around 1800 While running. Alright. I will try that with the straight edge. Thanks.
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Old 07-08-2013, 07:23 AM
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I laid a straight edge on the injectors this morning, they were all good. I pulled the injectors and the tips all look good, the crush washers were all crushed, and none of the o rings were gouged,cut or damaged.
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Old 07-08-2013, 08:02 AM
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Wow, you dont waste anytime, do you...

Alright, these problems your having, now that you fixed the f/p issue, how many miles are on the rig, since rebuilding/replacing, all that you've done? Theres air in both fuel and oil, thatthe system needs to expell out before the truck gets back to its 100% performance. Hell, i get white smoke at start-up, after changing my fuel bowl filter.

With, if any, minimal miles on rig, remove the chip, and let truck idle/run her to get miles up, to make sure alls good, prior to throwing ANY performance onto it...
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