Ford 6.0L Power Stroke Diesel :: 2005 - After Replacing Seals In HPOP Now No Start


Sep 9, 2016

I have a 2005 ford Excursion 6.0 with an EGR delete, bulletproofed beauty. I bought it about 8months ago and It ran great. I soon bought a 270amp DCpower alternator for it after the batteries died and then replaced the batteries. I eventually developed a no start when hot issue and decided to tear into it my self with everything I've learned on FTE! I love this site and most of you are like legends to me.... so I thought, how hard could this be?

So I bought that fancy icp pressure adapter for testing the pressure from the passenger side valve cover then found one that test pressure at the IPR port. So I went and bought that too 6 0L Powerstroke Specialist's Tool Kit Air Test Tool Ball Tube IPR Sockets | eBay and it lead me to multiple leaks on both sides of the oil rail.

I also bought the CTS2 insight and started monitoring things and realized I had more problems than I thought. I'm still learning how/what to look for and monitor. Anyhow, My EOT and ECT would sometimes be 30-40 Deg. apart. So knew I'd have to replace the oil cooler.

So here I am, I bought ALL ford OEM parts which were -- Oil cooler/standpipes/dummy plugs/ STC update/updated oil drain tubes/Coolant filter/bluespring kit/bango bolts/new degas bottle cap.

I put EVERYTHING in and was careful as can be. I located my leaks and it turned out to be the injector seals on #1 #2 and #5 injectors. The one on the top of the inside of the injectors. So then I bought all new ALIANT injector seal kits (all 8) might as well do them all while I'm in there. And put it back together. Still friggin leaked at injector 1 and 2. So I polished all the nipple cups and bought 8 new ALIANT seals for cups on the rail...STILL LEAKED (swear word).

After putting everything back together and taking it apart 6-7 times...I tried sticking the air directly into the injectors (#1,#2) using a rubber nipple and the injector spill ports were pissing out air. The rest of the injectors ports didn't leak at all except for #3 which was barely a leak.

So after some reading about this problem, I read that this "spill port" leak was normal and could be that the spools were probably closed so it was nothing to worry about. Or that's what I understood.

I put everything back together one more time and got ready for some "long cranking". I should mention I filled the oil valley from the filter housing (about a half a gallon) and cranked for 20sec...Waited 2 mins...cranked 20 sec...waited 2 mins.......continuously untill batteries went dead...then I recharged them and repeated...and recharged them and repeated...I knew It would take a long time but holy cow.

I used the CTS2 to watch my icp volts and it was 0.2 KOEO and while cranking. It didnt change. So I unplugged it. Now I have 1400psi. I tried using my other F350 ICP sensor and same thing. So Its not the sensor. Maybe the harness? So I unplugged the fcim and replugged it back in. Still wont start. I'm at my wits end with this and my wife is hating me for "trying to save money" and blocking the driveway for the last 9 days...

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Ford 6.0L Power Stroke Diesel :: 2005 F250 - New HPOP And No Start

I got a problem with my Ford F250 6.0 Diesel. The truck got a new HPOP but still wont start. ICP show everything between 15 und 75 PSI, it raises to 75 PSI max during cranking. The IPR shows 84,75% during cranking.

We get the code P0270 and P2285 in exchange but never together. We already checked the FICM but it looks good on the inside. I now ordered a new ICP sensor....

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Ford 6.0L Power Stroke Diesel :: 2005 - No Start - HPOP Reservoir Dry?

I've gone through every possible step in diagnosing myself but can't seem to figure it out. I do not have access to shop air to do an air test. Vehicle history that I know of: Has updated STC fitting, looks to be a reman hpop. I have tested the LPOP with the oil filter housing, fills quite fast, although no pressure registers while cranking on the gauge. When I opened the HPOP case to take a look, I found the reservoir dry. What can cause the LPOP to not feed the HPOP? I will be updating everything. The truck has relatively low KMs sitting at only 163,000.

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Ford 6.0L Power Stroke Diesel :: 2005 F250 Shifting Hard / Oil Leak Coming From Some Seals On The Turbo

This is is a truck I hardly know anything about. My wife bought it while I was deployed for herself and when it comes to vehicles she's an idiot. No, really she told me she bought it because at horse shows everyone else has one.

I noticed an oil leak and had a reputable shop look at it. They told me it was coming from some seals on the turbo. Long story short there is a brand new turbo on there, stock replacement. Now it seems very under powered and shifts hard. Pressing down anything more than 25% throttle will cause hard shifting or no shifting at all. It'll stay in second until I ease off the throttle.

I tried searching a few terms but I'm not sure what to look for. I don't know if someone has messed with the tuning. Broken clamp on the turbo. Replaced and everything is back to normal...

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Ford 6.0L Power Stroke Diesel :: Crank But No Start - HPOP Brand New Still No Pressure

05 excursion with 04 motor. 290k miles. Had a crank no start issue. Pressure tested hpop only got 450 pressure. So got a brand new on from ford. Also did standpipe, and dummy plugs. After forever and day of cranking truck fired up. Sounded great let it sit for 30 min. Took it out for ride, mile down the road lost all power. Alternator was bad, replaced that and battered just to be safe. Now truck won't fire and have zero pressure. Something that could of been tripped during power surge?

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Ford 6.0L Power Stroke Diesel :: 2004 F250 - No Start After Replacing IPR

The truck is a 2004 f250. Build date is 7/ 03 so its an early 04. I have been in a parking lot for 3 days now with no money trying to get this truck to start. Me and my dad replaced the ipr pigtail and the ipr thinking this might have been the problem, because the ipr pigtail had a damaged connector.

Before doing this work the icp sensor connector had no oil in it, now after replacing the ipr and cranking the engine the icp has some oil in the connector, could this cause a short and not let the truck start, and if so will unplugging the icp allow the truck to start?

We were having trouble with no starts before this happened and when it did all we had to was push the ground wire back further that goes back to the ficm and the truck would start, but that is not working anymore.

Is it possible the ipr is not seated properly or the new ipr is bad out of the box? Or maybe the made in tawain pigtail connector to the ipr is bad?

We are thinking it may be a short somewhere in the harness since everytime we pushed the ground to the ficm up further to where it grounds before when we had no start problems this might have took the short out of the ipr or icp pigtails and allowing the truck to start. Injectors are buzzing when key is turned and I can hear the fuel pump.

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Ford 6.0L Power Stroke Diesel :: Won't Start After Replacing Head Gaskets

Ran fine, did the head gaskets ,egr delete, oil cooler and 12mm dummy plugs. Primed the fuel system, oil pressure looks good on the guage , spins fine but doesn't seem to be making any attempt at starting . Gave it a shot of quick start and it never so much as kicked. Everything looks good, nothing leaking and nothing obvious. To top it off we are without power after Hurricane Mathew left his mark.

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Ford 6.0L Power Stroke Diesel :: Injectors Leaking Despite New Seals?

I have replaced all the injector seals as well as the ball cup seals but when I crank the truck over after a few cranks I see oil bubbling up from the top of all the injectors. When looking at the injectors from the "top" side all looks well but when I use an inspection cam from down below I can see this happening. Any thoughts?

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Ford 6.0L Power Stroke Diesel :: SCT On HPOP Can Be Upgraded?

Quick question, does an early 04 have an SCT on the HPOP that can be upgraded?

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Camry :: Replacing Seals And Water Pump On 2005 V6?

I am bringing in my V6 2005 Camry XLE in for a pulley recall and have reached 90,000 miles. The dealer told me I should also have the timing belt, water pump and engine seals replaced since they are all under the same engine side cover. I am considering the timing belt, but do I need to replace the oil seals and water pump?

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Ford 6.0L Power Stroke Diesel :: HPOP Cover Gap On The Back

When I pulled my HPOP cover the other day, noticed some RTV on each side where you have the small step down from the block and the piece of metal on the backside of the pump housing. The new gasket I installed had he step down and looked like it would fill the gap, but is the RTV necessary?

There was a previous leak on the turbo drain tube that the dealer I bought it from tried to stuff some kind of fiberglass material in there to absorb the oil. I half wonder if the dealer didn't try to "fix" the back of the cover leaking by cramming some RTV in there. I have to pull the cover again in a couple days and wanted to see if I needed to do anything special when installing the cover?

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Ford 6.0L Power Stroke Diesel :: HPOP Test For Air Leaks?

How does one pressure test for air leaks??? Truck is a 04/04 F250 with 198K ICP sensor in the valve cover.

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Ford 6.0L Power Stroke Diesel :: Oil Cooler Blowing Seals / Bypass Oil Filter Came Loose

I just replaced my factory oil cooler again, and my bypass oil filter came loose spraying 8 quarts of oil all over under the hood.

This is the second time it has done this. Both times my wife was driving so i don't know how it was running prior to this.

Now i think my oil cooler seal to the block is blown again! Just like the last time my bypass oil filter came loose.

Could this be a symptom of another problem?

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Ford 6.0L Power Stroke Diesel :: New HPOP / Low Pressure Oil Light Would Come On After Warm Up

Just replaced the hpop on my 04' 6.0. It had been down for about a year because my low pressure oil light would come on after warm up. Truck ran PERFECT, but dam light would come on. Eventually it wouldn't start by cranking, but would on a bump. (I have a 6spd.) still ran good. I would never run it over 5 minutes because i didn't want to damage anything. Finally getting around to fix it.

After a day of air testing, we tracked it down to hpop. (air coming out of turbo drain tube). I had a hunch that the dam bb on pump had spit out from similar stories on FTE, and thats what happened.

Replaced pump. (its an older style pump BTW, although i have a january 04 build and every ford parts guy said differently.) Put everything back together and now it runs terrible! We ran the truck for over 20 minutes and it didn't get better. I am afraid its gonna damage something to keep running it. My mechanic says 5 cylinders are misfiring and its something to do with the ficm or injector harness.... But, it ran perfect right before the hpop change???? Everything was double checked to make sure it wasn't something dumb.

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Ford 6.0L Power Stroke Diesel :: 2003 XLT - HPOP Cover Leaking

A good friend of mine just bought a 2003 xlt with the 6.0 and has an oil leak at the HPOP cover as far as he can tell. Looking for a good write up that explains how to get to where we need to go. Also maybe a list of o-rings and gaskets that will be needed on the journey. Is there anything else that may need attention while we are in that deep. I have read about the SVT fitting but not sure what that is or where. The EGR has been deleted.

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Ford 6.0L Power Stroke Diesel :: 2013 - HPOP Dead Again - Reason?

July 11, 2013 replaced HPOP. June 26, 2014, Going down I20 in Dallas engine shuts off. Three days later Ford techs declare said HPOP dead . Looking at another HPOP along with stand pipes and dummy plug seals. Hopefully I can get some warranty relief on the pump. Do these things eat HPOP?

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Ford 6.0L Power Stroke Diesel :: 2003 F350 - Low HPOP Pressure

2003 f350 6.0. Ran last night and wont start today. Monitor says 85 psi pressure, should be atleast 500 to start. Could it be the IPR?

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Ford 6.0L Power Stroke Diesel :: 2003 - New HPOP / Pressures Too High?

Finally got the hpop in my 03 done, got it fired up and runs great. The longer crank times seem to be getting better, however I am a bit concerned when I really get into her I am seeing pressures of 3400 psi......seems high to me. I guess I don't know for sure what the IPR was reading, will have to check that. Truck runs great, nice and smooth, but I am afraid I am going to blow something.

What is normal and what is not? Is there a way this pump will dump excessive pressures if needed? Or is it just a matter of time before I blow an oring out somewhere? I'm not sure how much the pump is capable of putting out. At idle it's sitting right around 630 after warmed up, maybe a bit lower.

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Ford 6.0L Power Stroke Diesel :: 2003 Will Not Restart Again After Engine Gets Warm / Bad HPOP?

2003 with hot no start issues. It starts fine in the morning however will not start again after the engine gets warm, after an hour or so of cooling off it will eventually go. Not sure if I should start with.... Readings below ....

FICM L 13.5v
FICM M 48v koeo and 47 running
IPR 14.7% koeo
IPR 74.6% cranking (no start while hot)
IPR 40% (after cold start while running
ICP 737psi cold start
ICP 1600psi engine running 2k rpm
ICP 360 hot while cranking

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Ford 6.7L Power Stroke Diesel :: Grayish / Blueish Smoke On Cold Starts - Turbo Oil Seals Leaking

I've been getting some grayish/blueish smoke on cold starts lately and decided to do some investigation to see if there was a problem or just the cold temps.

I googled it and turbo oil seal problem was pretty common so I figured it was easiest to start there. I removed the pipe between turbo and CAC and it had quite a bit of oil it in. The pipe after the CAC had a fair amount as well. I checked the oil level in the engine and it was slightly down but I can't say how accurate the dipstick is nor it was completely full after the last oil change. Either way, not much oil is entering the intake but I would assume any is too much.

Here's my main concern - What's the likelihood of getting a runaway from this?? Is it possible for the oil seal to fail 'more' than it already has putting more oil in the intake allowing for a runaway condition?

Obviously the turbo needs replaced but is it safe to run it the way it is until it completely fails or replace immediately?

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Ford 6.0L Power Stroke Diesel :: 2003 - Weak HPOP / High Pressure Oil Leak?

My 03' 6.0l hpop only makes about 1700 psi at wot, at hot idle the ipr is 25.1 and the icp is about 580. It runs pretty good but it seems the crank time to start is getting a little longer sometimes, other times it fires right up. It makes no difference if its hot or cold. Do pumps get weak or do you think I have a leak?....

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