Oil cooler/IPR replacement no start.

[deezul]

I have been away sick from work for a while, when I returned I had a few dead heads here. Shop foreman replaced egr cooler and oil cooler on '05 f350. It started, ran fine then stalled. IPR valve full of sand when I removed it. Replaced valve, flushed system and truck would start (a little hard), truck ran fine, performed fine (IPR and ICP were slightlty elevated @ 750-800RPM 30%, 800ICP). Once the unit is shut off, it will not restart. Unplug the ICP and crank for 10-15 seconds and it will eventually catch and start. Runs ok. When cranking ICP pressure fluctuates from 200-500. Performed audible air test to check for HPO leaks but can't really hear anything (other than the usual slight "hissing" of air coming from HPOP seal). Is there something that the foreman has missed when re-assembling the oil cooler? He informed that yesterday when he ramped the IPR to 85% and then back down to 15% it started with no issues. He has replaced two IPR's and I replaced the original. I monitored base pump flow by removing the filter and holding the check valve down, housing filled in 4-5seconds. Any help would be greatly appreciated as I am very, very backed up...

[blown99]

This engine had no hard start issues before the oil cooler replacement? Did he replace the screen in the oil reservoir? If he didn't then I would suspect that the screen is probably torn and allowing the dirt to stick the IPR valve. The ramping up of the ipr duty cycle, then it starts, suggest (to me) that there is debris being dislodged from the IPR during that process, allowing it to work for a short time.

[Jim Warman]

Remove the oil filter and repeat the air test... if the IPR was full of sand, it had to pass through something that doesn't like sand to get there.

 

I don't think it was too long ago that we were discusing contaminated oil coolers.....

[deezul]

I removed the oil filter Jim and pressurized the system. You can hear bubbling and gurggling coming from under the oil filter housing. The sand isn't casting sand, it seemed like the valley wasn't cleaned as thoroughly as it could have been...

 

I'm not sure what the gurggling from under the housing indicates? Pushing the check valve down doesn't change the sound.

[mchan68]

I'm not sure what the gurggling from under the housing indicates? Pushing the check valve down doesn't change the sound.

 

 

If I'm not mistaken, there was some discussion to the effect, that if pressurizing the high pressure oil system revealed air leakage into the oil cooler housing, the high pressure pump was to be condemned.

[cbriggs]

I've also heard that as well Mike. Maybe bump the engine over a bit and air test again, to see if moving the hp pump pistons has any effect on the gurgling? Every hp pump I have changed has been a catastrophic failure, so I have never done that test.

[deezul]

Same here. I have never used this test before. All HPOP's that i have replaced have also been complete failures.

 

 

@Mike: What post was this discussion in about the hpop?

[lmorris]

I also recall that discussion. IIRC it was mainly on the old style pump because they typically fail more than the new ones.

[Jim Warman]

We have used this test as an indicator for HPOP replacement... a positive displacement pump shouldn't have anything going through it in the wrong direction.

 

Scott, whether the sand is from poor housekeeping in the engine valley or from poor housekeeping with inspecting new parts and assemblies is a moot point. If the IPR is full of ANYTHING it was either there to begin with or it had to pass through the HPOP to get there.

 

FWIW.. you have an audible air leak - it just isn't where you expected it.

[deezul]

Well, HPOP it is! Have never used this test before, I've only done three pumps in my couple of years and those were due to catastrophic failures. I really appreciate the information! I was pretty sure that if gurgling is heard under the filter than air SHOULD NOT be bypassing the pump...