New injectors, running poorly - PowerStrokeNation : Ford Powerstroke Diesel Forum
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post #1 of 21 (permalink) Old 11-17-2019, 04:59 AM Thread Starter
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New injectors, running poorly

New injectors, total buzz test failure
Hello all. First time posting to the site. I have a 1997 F250HD 7.3 manual ZF5 short bed crew cab with 207,000 miles. I have owned the truck for 4 years and roughly 40K miles. Until recently the only engine mods have been the AFE cold air intake and MBRP 4" turbo back exhaust with cat delete and 3" downpipe. I change the oil every 5K miles and always run Rotella T4 15W-40 and Wix XP oil filter. I also change the fuel filter every 10K miles with Wix filter. Overall I think the truck has run well considering it is 22 year old. Cold starting seemed to be the only nuisance. It is my daily driver and is parked in the garage. When starting in the morning if I drove it the day before it would fire up pretty quickly, but if left for a few days starting up would take quite a bit of cranking and lots of black to white smoke. Once running idle seemed to be decent but not great. All of this i chalked up to the quirks of an old diesel truck.

A few weeks ago I decided to see if I could improve the cold start. I inspected the wiring harness connections and found the pigtail connections on the rear of the motor were fried. Looked to be the glow plug connections for #5, #7 and #8 were all bad. Instead of just replacing the connectors I decided to jump in and replace the injectors, valve cover gaskets, glow plugs and pigtails. I ordered 8 Full Force Stage 1 180cc injectors, 2 new Alliant valve cover gaskets/harness, 4 new Alliant pigtail connectors, and 8 new Motorcraft glow plugs. To run the upgraded injectors I also purchased the PHP Hydra chip (no chip had been run on the truck before). Last weekend I installed everything without issue. Truck fired up super fast and seemed to be great even after sitting for a few days.

Then I did some test drives and noticed some issues. At low speeds all seems well, First to second shift good, second to third shift good, but above that the truck shifted really funny. When accelerating in third gear up above 1500 rpm and then engage the clutch to shift the rpm's would drop drastically down below 400. If I tried to engage the next gear as normal the truck would "clunk" as if it was hesitating. This was true in the next shift forth to fifth as well. Also if I waited to engage the next gear the rpm's would drop below 400 and bounce back up to 650. This would happen about three times until the engine leveled off at normal idle rpm of 650. If i keep the shift points below 1500 rpm it doesn't seem to be as bad, but if I step on it and get above 1500 - 3000 rpm it is really bad. Additionally if i really step on it in the lower gears, say 3000 rpm shift from second to third there is no issue and shifts perfectly.

So here is what I have done so far to fix the issue.
- replaced EBPS (both the sensor and the tube. I made sure to clean out the bracket at the sensor and the connection to the manifold as well.
- checked ICP sensor and found some oil in the connection. Replaced with new sensor.
- opened valve covers again and re-torqued the injector hold downs (all good)
- visually inspected wiring and connections (all good)
- replaced CPS
- OHM tested the injector wiring and harness at the injectors all the way back to the IDM. (all ohm tests were good and all continuity checks were good)
- buzz tested injectors using OBDlink MX+ wifi dongle to iPhone app FORScan.

Here is where I really get confused. the buzz test runs and all the injectors buzz appropriately and sound the same. I did this with the motor both warmed up and the next morning totally cold. Each time the test comes back with failures to all injectors. Here are the codes...

P1271 to P1278, P1293, P1294, P1298 all failed.

I also removed the Hydra chip to see if that made a difference. The buzz test results are the same but the truck did seem to run better, but with less power of course. The shift issues also seemed to clear up as I did not get the rpm flutter between shifts.

The only other thing I can think of is a failing IDM. Before I keep throwing money at the issue I was hoping there were some more diagnostics I could do. Any help would be greatly appreciated.
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post #2 of 21 (permalink) Old 11-17-2019, 02:42 PM
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Re: New injectors, running poorly

With all those codes, I would try an idm out. See if anyone will swap you for a test or run to the junk yard and buy a cheap one. I might of missed it but did you change the pigtails too?

01 f-250, Standard
Rev tech 4" lift, 37" military wrangler Mt tires
KC diy 66, Full force 160/100 and custom tunes from PHP
Banks intercooler and full 4" exhaust, Diy S&B intake
Diy quad feed, Hydra, Isspro boost, pyro, and fuel pressure
3/0 battery cables with military style terminals
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post #3 of 21 (permalink) Old 11-17-2019, 04:23 PM Thread Starter
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Thanks. Looks like I will be hitting the junkyard today. Just so happens the one close to me just received a 94 F250 7.3. Would an idm from that work in my 97?

And yes I replaced the pigtails as well.

97' F250HD 4x4 ZF5 CCSB
BFG 285-75R16 tires/Bilstein 4600 shocks/3.54 gears/Front SAS Dana 60/Rear Sterling 10.25/TruTrac LSD/AFE Stage 2 cold air intake/MBRP 4" turbo back exhaust, cat delete, 3" downpipe/Full Force stage 1 180cc injectors/Hydra chip/Clutch pedal heim mod/Marinco mod/Hutch & Harpoon mod/Anzo Halo headlights and taillights
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post #4 of 21 (permalink) Old 11-17-2019, 07:46 PM
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Re: New injectors, running poorly

Lotsa upgrades nice.... the CPS and ICP are Ford OEM parts yes? Sometimes the “new” none OEM replacements will give you grief.

Are you running stock HPOP and can you check HP oil to ensure you have enough, I’m thinking you are running out of HP oil.

Have you checked your fuel pressure and is it stock or electric, most injectors like around 62-65 psi at idle. If stock you can check via the schrader valve. Do a search on shimming fuel pressure regulator (stock) as you can increase fuel pressure with this mod. Lastly, I’d run a boost fooler in-front of the MAP sensor. MAP sensor gets confused when over boosted above 24 psi and will revert to ECM fuel tables, which can cause problems with aftermarket tunes. Boost fooler can be made or RiffRaff Diesel sells them too, limits boost seen by MAP sensor to 21-22 psi.
j

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post #5 of 21 (permalink) Old 11-18-2019, 01:05 AM Thread Starter
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Re: New injectors, running poorly

Yes, the ICP, EBPS and ICP are all Ford OEM.

I am running a stock HPOP. I thought about checking the HPOP oil level but someone prior to me stripped out the filler nut. I was going to do a search on how to get it out when stripped. I am also running the stock fuel bowl (not electronic fuel). I will do a search on how to check the fuel pressure and see about the shimming mod. I planned on doing the boost fooler later this month.

It seems to me that all of these items above are only addressing the RPM flutter with the chip in at higher RPM shifts. I currently am running the truck without the chip and while it is shifting better and doesn't have the rpm issue it still seems to be running rough. This makes me think that there these are two separate issues. This is further backed up by the total failure of the buzz test.

This brings me back to the IDM. Junkyard run was a failure today. Their inventory search had an incorrect listing and did not have a 7.3. Unless anyone has other ideas I am going to have to drop some more coin on an IDM this week.
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post #6 of 21 (permalink) Old 11-18-2019, 03:15 AM
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Re: New injectors, running poorly

Just so you know. Any idm from 94.5-03 will work. What did you use to connect the pig tails to the engine harness? I would go and check all those connections.
I too think there is two issues but tell you get all the codes figured out, I wouldn't be messing with the shifting issue. It could be a few different issues but we will get to that when it's running good.

01 f-250, Standard
Rev tech 4" lift, 37" military wrangler Mt tires
KC diy 66, Full force 160/100 and custom tunes from PHP
Banks intercooler and full 4" exhaust, Diy S&B intake
Diy quad feed, Hydra, Isspro boost, pyro, and fuel pressure
3/0 battery cables with military style terminals
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post #7 of 21 (permalink) Old 11-18-2019, 03:25 AM
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Re: New injectors, running poorly

Something to add to Sbluke's post,

If you used Doorman Harnesses, the wire colors are funky, and really easy to get them crossed.

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post #8 of 21 (permalink) Old 11-18-2019, 03:39 AM Thread Starter
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Re: New injectors, running poorly

I used Alliant harness and Alliant pigtails. I soldered the pigtail wires to the engine wiring harness. I believe the connections are solid and accurate but started to doubt myself, so last night I went over all the wiring again back to the IDM and everything checked out.

BTW... thank you all for this feedback. I LOVE my truck and really want it to run well.
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post #9 of 21 (permalink) Old 11-18-2019, 08:12 AM
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Re: New injectors, running poorly

Quote:
Originally Posted by cainbr View Post
Yes, the ICP, EBPS and ICP are all Ford OEM.

I am running a stock HPOP. I thought about checking the HPOP oil level but someone prior to me stripped out the filler nut. I was going to do a search on how to get it out when stripped.
What I mean by enough oil is whether the output of the HPOP is adequate to drive injectors. If you dont have access to Auto Enginuity or a scanner that will monitor pump pressure you could always hook up a liquid filled gauge into any of the HP oil plugs on the head with a length of high pressure hose and monitor. I have one in my shop I use periodically its a 5000psi gauge and 5ft length of high pressure line.

In regard to fill plug on top of HPOP Reservoir you can always undo the oil pressure sensor on the passenger side top of Reservoir. Can also helicoil the oil plug itself, but kind of a hassle as you have to remove the Reservoir. If the fill plug Allan head is stripped just pound a larger Allan socket into the hole and undo it, the plug itself is an odd metric thread, RiffRaff has plugs I think.
j

Tan white tan 97 ECLB, D60 PMF, RSK SD springs front, airs bags rear, 4:10s 37 Toyo R/Ts intake, FFD 205/30s, DP 4 exhaust DIY E-fuel, ZF-5 now
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post #10 of 21 (permalink) Old 11-18-2019, 03:26 PM Thread Starter
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Re: New injectors, running poorly

Thanks JCart. I don't have access to Autoenginuity or a scanner that will read pump pressure. I will do the pressure test with the gauge and high pressure hose. What psi should it read?
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