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Discussion Starter #1 (Edited)
Hi All

I've been tracking down a knocking/tapping noise from my 7.3 powerstroke - stock minus turbo back exhaust system.

My truck is a 1996 F350 7.3 dually 2wd with 195000 miles on her.


So far I have replaced the leaking fuel pump

Replaced the filter housing and filter

Replaced the burnt injector harness and valve cover Gaskets

Replaced the glow plugs with new motorcraft plugs

Changed the oil and filter as well as the oil in the HPOP reservoir - I also added Archoil to see if it would quieten down the injectors from stiction

Now I have two noises one that sounds like a gas lifter tick and another deeper knocking noise

I have done an injector buzz test and they are all buzzing good with no lazy buzzes but it did throw an error

20191224_140405_1578539420955.jpg
20191224_140346_1578539454648.jpg

Also done a cylinder contribution test and it passed

20200108_160611_1578539680128.jpg

I ran another test and it came back with p0476

20200108_160852_1578540924710.jpg

I also did some acceleration runs monitoring my icp pressure and it seems I top out at 2400psi





Another question I have is what is this fitting on my turbo for? - there is exhaust coming out of it and i dont know what was hooked up to it.
There is a guage on my dash that doesn't work and it says brake pressure it's a BD Diesel guage and I do have an exhaust Brake installed from BD Diesel is that fitting on that turbo where the guage ties into?

20200102_112426_1578541514981.jpg

I pulled the valve covers and ran the truck while watching the oil deflectors on each injector and there is a small trickle of oil coming out of the injectors - not sure how much should be coming out.

Thanks all
 

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Discussion Starter #2
now when I soldered in the new pigtails I noticed that the color coding on the new pig tails did not match up with the pin positions of the old harness- so I ignored the colour coding and cut the wires one by one and soldered them to the same position wire on the plug -

20191230_220519_1578542864503.jpg
 

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What is your fuel pressure at? Sounds like a dead cylinder either from injector not properly firing or compression.

With that mileage I doubt you have a mechnical problem unless the maintenance was poor.

You can swap injectors around and see if that buzz test failure follows it.

Does the ICP connector have oil in it?
 

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Discussion Starter #4
What is your fuel pressure at? Sounds like a dead cylinder either from injector not properly firing or compression.

With that mileage I doubt you have a mechnical problem unless the maintenance was poor.

You can swap injectors around and see if that buzz test failure follows it.

Does the ICP connector have oil in it?
I will take a look at the connector tomorrow

I'm thinking about purchasing a set of single shot injectors and throwing them in as i'm positive they are the originals.
 

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Buy aftermarket injectors.

Split shot were cali motors and 99+ 7.3. OBS has the single shot as a stock injector. Yours appears to be the Cali model.

You will need tuned for single shot injectors.

@[email protected]
 

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If your truck is a late 96 Cali model you could have splits (not real common however). If that was the case, you would have a DPC-202 PCM with a MIF-series program for and auto trans or a DPC-203 PCM with an AUG-series program for a ZF-5 speed. Verify those before you get new injectors (solenoids can be replaced, so it's not a definitive indication of splitshots). If you have a DPC-311 or DPC-312 PCM you would have a 97 California truck. Cheers!
 

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Discussion Starter #8 (Edited)
If your truck is a late 96 Cali model you could have splits (not real common however). If that was the case, you would have a DPC-202 PCM with a MIF-series program for and auto trans or a DPC-203 PCM with an AUG-series program for a ZF-5 speed. Verify those before you get new injectors (solenoids can be replaced, so it's not a definitive indication of splitshots). If you have a DPC-311 or DPC-312 PCM you would have a 97 California truck. Cheers!
Thanks for the info
Is there a sticker on the PCM that will show me this?

20200109_185105_1578624680647.jpg

Edit: found this one under the kick panel

20200109_190936_1578625827828.jpg
 

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Based on the 2nd pic, you have a late 96 Cali truck (so it would have splits). Easy enough to change over to single shots if you wanted. Just need to change programming. Cheers!
 

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A set of 160/0 injectors and a DIY turbo upgrade would do well for you. Or you could just install a stock replacement set of AD code, which are slightly larger. In either case the DIY turbo upgrade will do well.

https://cncfab.us/i-30498082-full-force-diesel-stage-1-injectors-160-180-0-full-7-3-stg1-r.html

https://cncfab.us/i-30498147-full-force-diesel-99-5-03-7-3l-ad-injectors-full-7-3-ad-r.html

https://cncfab.us/i-30498942-kc-turbos-94-03-7-3l-s300-turbine-360-bearing-billet-wheel-kit-300317.html
 

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Discussion Starter #11
A set of 160/0 injectors and a DIY turbo upgrade would do well for you. Or you could just install a stock replacement set of AD code, which are slightly larger. In either case the DIY turbo upgrade will do well.

https://cncfab.us/i-30498082-full-force-diesel-stage-1-injectors-160-180-0-full-7-3-stg1-r.html

https://cncfab.us/i-30498147-full-force-diesel-99-5-03-7-3l-ad-injectors-full-7-3-ad-r.html

https://cncfab.us/i-30498942-kc-turbos-94-03-7-3l-s300-turbine-360-bearing-billet-wheel-kit-300317.html
Hey Cory

Are you guys able to reprogram my ecu for these injectors?

Thanks
Adrian
 

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Discussion Starter #12
One thing I noticed was if I accelerate and let off there is a period as the rpm drops where I hear the knock quite loud for a brief period.
 

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Do you have an automatic trans? This is a symptom of a failing BPS.

Your MAP, BPS, and EBP sensor should all read the same with KOEO.

BPS = Barometic Pressure Sensor
 

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Discussion Starter #14
Do you have an automatic trans? This is a symptom of a failing BPS.

Your MAP, BPS, and EBP sensor should all read the same with KOEO.

BPS = Barometic Pressure Sensor
Yes automatic E40D
I will plug in today and see what the readings are

Thanks,
Adrian
 

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Discussion Starter #18 (Edited)
Removed the injectors and cleaned all the garbage from the cups
Replaced my exhaust back pressure sensor and installed a new air filter as my brand new stock filter disintegrated
I ended up ordering a Hydra tuner and injectors just waiting for them to arrive.
She runs alot better since pulling the injectors and reinstalling
 

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Discussion Starter #19 (Edited)
Got my injectors and Hydra Chip installed and no more knock
I did have some connectivity problems with the Hydra chip I ended up adding solder to the chip connectors on the PCM which fixed the problem -I made a short video about it - https://youtu.be/rKXSM6S-bso

So happy with the truck now so much more power.

https://youtu.be/EShmYur3I0E

Hope this thread is helpful to someone at some point
 
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