oldmanriver
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Below is a write up from a friend who is experiencing the issue any/all help is appreciated. Thanks
While driving stalled out. Went to start and experienced crank no start with grey/white smoke coming out of exhaust. First thing I did was tow vehicle and checked codes. ***Found Code P2291 I’ll try to keep this in order as much as possible and explain the diagnostics steps taken as it’s been almost 3 months now with the truck down. I first went after checking wiring and sensors. I replaced: -oil pressure switch (no change) -crank and cam sensors (no change and are syncing) -checked fuses and inertia switch (all good or in working order) I then watched live data when cranking and discovered no fuel pressure at the fuel rails. The PVC and VCV were both giving feedback. (VCV maintained ~33% while the PCV value raised to ~ 53%) I ordered fuel bleed kit with shader valve to bleed from fuel cooler. -checked psi at the low side of fuel cooler and read ~ 5 psi. (air dog lift pump/installed for ~two years) After referring to diagnostic manual the fuel pressure sensor was in question so replaced the sensor. -after replacing frp sensor (duralast brand) the fuel pressure built on second crank to barely match the desired fuel pressure (still no start) FRP voltage value .49 volts at key on. -after cranking again the fuel rail pressure spiked up over 130,000kpa (~18,000psi) ***Simultaneously the PCV value dropped down to zero and slowly climbed back up. -the following crank had no fuel pressure. I then decided to order HPFP and install kit including new high pressure fuel lines. /after installing HPFP (with new harness gasket and hp fuel lines) -Bled system -cranked (no change) While waiting for parts in sent in my vin and had a new updated ecm programmed. Installed new ecm and programmed two sets of keys and satisfied PATs programming. Tested out and ecm communicating with the truck ie injector buzz test, key on engine off test passed. Drained fuel from tank (sump installed with air dog lift pump ~ two years prior), Added 15gallons of new diesel fuel. replaced fuel filters on lift pump and secondary filter on top of motor (motorcraft) did not see “glittering” but did see a couple small specs of metal in the bottom of the fuel filter housing. Cleaned out fuel bowl and installed new filter. Replaced all (8) injectors with new OEM injectors. While under the rocker covers: Replaced FRP sensor with Ford OEM part. Swapped out glow plugs for all new. Cycled key and Bled fuel system. **First crank no fuel pressure. VCV maintained ~31% and climbed to ~51%. (Air present in bleed kit line. Bled more and when had just fuel attempted to start again) **Second crank truck started and idled steady at 690 RPM Desired fuel value was met and injectors were controlled on. VCV~ 24%. PVC ~15% After idling for a few minutes I shut the key off and restarted. Truck started again without issues. Revved motor few times between 1500-2800 rpm and all sounded and seemed good to go without any hesitation or odd noises. Let idle for few more minutes. Truck stalled and was back to the same scenario. After days of trying to bleed the system and changing my starter from cranking I decided to try another new hpfp. I’ve read on forums people trying multiple hpfp replacements before succeeding. By this point I’m exhausted mentally and financially. I since have checked torque specs on injectors and fuel lines, conducted a mist test, and compression testing. Compression Test: Cylinder 7-(420psi)…..8-(347psi) 5-(365psi)…..6-(390 psi) 3-(457psi)…..4-(425psi) 1-(405psi)…..2-(410psi) Mist test: injector for cylinder # 8 consistently spraying fuel from glow plug hole while cranking. Swapped injectors #6 and 8 to observe the mist change cylinder locations. Oddly the mist cleared up to lil or no mist after cranking to clear cylinder 8. Any help is appreciated as the truck is still down. Reading ~ 690psi on fuel rail and has grey smoke out exhaust while cranking. Fuel injector and pump adaptive tables were reset. No diagnostic trouble codes present since it started and ran for the short period of time.
While driving stalled out. Went to start and experienced crank no start with grey/white smoke coming out of exhaust. First thing I did was tow vehicle and checked codes. ***Found Code P2291 I’ll try to keep this in order as much as possible and explain the diagnostics steps taken as it’s been almost 3 months now with the truck down. I first went after checking wiring and sensors. I replaced: -oil pressure switch (no change) -crank and cam sensors (no change and are syncing) -checked fuses and inertia switch (all good or in working order) I then watched live data when cranking and discovered no fuel pressure at the fuel rails. The PVC and VCV were both giving feedback. (VCV maintained ~33% while the PCV value raised to ~ 53%) I ordered fuel bleed kit with shader valve to bleed from fuel cooler. -checked psi at the low side of fuel cooler and read ~ 5 psi. (air dog lift pump/installed for ~two years) After referring to diagnostic manual the fuel pressure sensor was in question so replaced the sensor. -after replacing frp sensor (duralast brand) the fuel pressure built on second crank to barely match the desired fuel pressure (still no start) FRP voltage value .49 volts at key on. -after cranking again the fuel rail pressure spiked up over 130,000kpa (~18,000psi) ***Simultaneously the PCV value dropped down to zero and slowly climbed back up. -the following crank had no fuel pressure. I then decided to order HPFP and install kit including new high pressure fuel lines. /after installing HPFP (with new harness gasket and hp fuel lines) -Bled system -cranked (no change) While waiting for parts in sent in my vin and had a new updated ecm programmed. Installed new ecm and programmed two sets of keys and satisfied PATs programming. Tested out and ecm communicating with the truck ie injector buzz test, key on engine off test passed. Drained fuel from tank (sump installed with air dog lift pump ~ two years prior), Added 15gallons of new diesel fuel. replaced fuel filters on lift pump and secondary filter on top of motor (motorcraft) did not see “glittering” but did see a couple small specs of metal in the bottom of the fuel filter housing. Cleaned out fuel bowl and installed new filter. Replaced all (8) injectors with new OEM injectors. While under the rocker covers: Replaced FRP sensor with Ford OEM part. Swapped out glow plugs for all new. Cycled key and Bled fuel system. **First crank no fuel pressure. VCV maintained ~31% and climbed to ~51%. (Air present in bleed kit line. Bled more and when had just fuel attempted to start again) **Second crank truck started and idled steady at 690 RPM Desired fuel value was met and injectors were controlled on. VCV~ 24%. PVC ~15% After idling for a few minutes I shut the key off and restarted. Truck started again without issues. Revved motor few times between 1500-2800 rpm and all sounded and seemed good to go without any hesitation or odd noises. Let idle for few more minutes. Truck stalled and was back to the same scenario. After days of trying to bleed the system and changing my starter from cranking I decided to try another new hpfp. I’ve read on forums people trying multiple hpfp replacements before succeeding. By this point I’m exhausted mentally and financially. I since have checked torque specs on injectors and fuel lines, conducted a mist test, and compression testing. Compression Test: Cylinder 7-(420psi)…..8-(347psi) 5-(365psi)…..6-(390 psi) 3-(457psi)…..4-(425psi) 1-(405psi)…..2-(410psi) Mist test: injector for cylinder # 8 consistently spraying fuel from glow plug hole while cranking. Swapped injectors #6 and 8 to observe the mist change cylinder locations. Oddly the mist cleared up to lil or no mist after cranking to clear cylinder 8. Any help is appreciated as the truck is still down. Reading ~ 690psi on fuel rail and has grey smoke out exhaust while cranking. Fuel injector and pump adaptive tables were reset. No diagnostic trouble codes present since it started and ran for the short period of time.
