Air leak test clarification question - Ford Powerstroke Diesel Forum
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Old 05-25-2014, 10:55 AM
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Air leak test clarification question

Still trying to resolve my issues as time permits...
When testing for air leak should there be absolutely NO leaks with IPR energized? I have a SLIGHT leak at IPR dump hole at rear of pump while energized, can't hear it but I can feel it seeping a bit...

All new seals including nipple cup seals and new motorcraft stand pipes and dummy plugs... and I still have an air leak on drivers side besides this small seepage at rear of pump
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Old 05-26-2014, 11:19 AM
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reassembling without a solution

The leak at rear IPR dump is very slight while energized and I am out of time with this repair. I am reassembling hoping that it is normal.
I do still have a leak at 2 injectors but have re-replaced the top o-rings and nipple cup o-rings even though they show no ill signs. I cannot find the actual leak, but can hear the hiss.

I must run it like it is and recoup some time and money to go back in.

I believe the air I hear near the branch tube/ stand pipe connection is the sound of air movement not a leak in that area.

Can the injector leak elsewhere?

I hate buying parts to throw at a problem but my o-rings look perfect and of course are new.
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Old 06-08-2014, 07:20 AM
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finally back together.

Work takes too much time away from all the important things in life...lol
I finally have the truck back together.
I learned (on another forum) that sometimes with the key off and air testing the air can flow past the injector solenoids and I was hearing air flow and not a leak.
Seems good now but have only tried a couple restarts after heat soak. Today will see a lot of driving and restarting.
The problem turned out to be top O-rings that failed after 1500 miles. they were ISK parts and they are Alliant this time.
I did replace the dorman cooler and seals with ford parts even though the seals in the dorman seem to be updated now as there were no degradation and the seal is no longer green.
anyone need a good (dorman) oil cooler? just need a new seal set from ford...I will sell it for $100.
I have also replaced the banjo bolts to the updated 6.4 parts.

Thank you everyone for trying to help...I do love my 6.0...
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