Ford 6.0L Power Stroke Diesel :: Long Start - HOP Would Fire Injectors And Start Up After Several Tries

Had long start issues. Would turn over for 5 seconds - shut off- turn over for 5 seconds - shut off - third try on 4-5 seconds the low oil pressure would come up and HOP would fire injectors and start up.

Was not sure what was up, so look it to Ford. They did leak down test and found seal at the top of injector 4 was leaking. Replaced it and leak moved to other injector. Basically moving to the next weakest seal point. I told them to stop as i did not want to pay, parts, labour and shop time to replace all injectors, etc. They also said power across all injectors was good, but 3 & 7 were not contributing on cold start.

I drove it home and bought parts. New cups and seal for all 8 on fuel rail. New gasket kits for injectors. Plus 2 new injectors to replace 3 and 7.

Replaced injectors in 3 & 7 with the 2 remanufactured i bought. Replaced all cups and seals on fuel rails. So it has new injectors in 3, 4 & 7.

As for the other injectors i took the 5 of them right apart and cleaned them and re-assembled. Took about an hour per injector, took my time to get it right, just FYI. Went pretty good i thought. Seemed pretty straight forward actually.

Now no start - no high oil pressure at all. LOP comes up right away. Scanner shows no HOP no matter how long i crank it.

FICM power good, 47.5 - 48
shows FICM sync - YES
IPR sits at 14% and jumps to 84% on crank - starting, see photos below.

Scanner prior to crank

Scan during crank

Note zero IPC - PSI

Right now.... Got the valve cover off on passenger side. Cannot see oil squirting out the sides of any injectors, but line of sight is limited. Maybe need a small mirror to see in there. LOP comes up better than it has in years, but no HOP now. Before rebuild it seemed i had good HOP but low LOP.

I drove it home from Ford and into my garage, so i do not believe the HPOP crapped out sitting in the garage, so i am ruling that out as a fail, at this time.

Dummy plugs were replaced 5 years ago and o-rings looked decent.

Pulled the small plug screw at the top of the fuel rail. Cranked it until oil came out, bleeding air. then replaced the screw plug. Have not done that on drivers sideyet. Will try that tomorrow. However, think this is more than an air issue, as i have cranked it over plenty, unless i just have that much air.

Going to pull the valve cover on the Driver's side tomorrow. Then will have both covers off at same time to view all.

Noted that if i put compressed air into the screw hole on top of the fuel rail, i can hear air coming out from below the fuel rail. Nothing at the base or around injectors. Does not seem to be at the cups either.

Just wondering.... Buy applying air to those screw plug holes, is that the same as doing the air test at the sensor that pokes up through the valve cover.

With air pressure at these scew plugs on the fuel rail, should this be sealed and be air tight and hear no air leakage. Because it was not air tight on the drivers side before i closed that side up. I am curious about this.

I am assuming i still have a HOP leak. I do not think i have a failed HPOP. How to better chase a HOP leak?