dommertl
SDD Junior Member
Buddy of mine has 6.0 that wouldn't start when hot. Took it to dealer, 3weeks before they would look at it. He took it to another shop and they said they would cut him a deal. Said it was the HPOP and they would replace it and if that wasn't it then they wouldn't charge him labor. They would continue replacing parts till they fixed it. HA!!! I did some research here and told him we could tackle it at the house.
1 1/2 hours to get to the turbo for removal then disaster strikes. The third bolt down bolt (in the back) strips the head on the bolt. Tried several different stripped head bolt removal devices and none worked.
Dropped the down pipe for easier access to the bolt (1 hour). Ended up cutting the head off with a cut off disc. Worked great. Total time from start to turbo on ground 4 hours.
Removed the IPR and HPOP cover (8 ea 8 mm head bolts three of which are under the egr tube on the passenger side (tight but workable) and 2 ea in back holding exhaust heat shield. The cover requires some inventive manuvering to get out(more on this during reassembly). Removed the HPOP and checked the quick disconnect. Not cracked (1 hour). So we continued on to the next item.
Removed the valve covers (2 bolts on passenger side next to the heater box difficult to get to but doable) and the HP oil galleys (logs?) 1 hour. Checked o rings on stand pipes (back end of engine) and they were good. NOTE: Remove 10 mm head allen head plug before removing oil galley and it will come out easily.
Removed dummy plug on top front side of oil galley to check O rings. AHA!!!
Found the bottom o ring on each dummy plug deteriated and burnt looking. This allowed oil to go back to the crankcase when hot instead of maintaining oil pressure.
Spent $90.00 at dealer for needed o rings and upgrade for HPOP quick disconnect.(the upgrade eleminates the quick connect and becomes a solid unit that screws into the HPOP).
Started reassembly in reverse order.
NOTE:
When you get to the HPOP cover plate, cut off the taller exhaust shield tab on the passenger side and the plate goes on with minimal effort(Install the three bolts under the EGR tube on the passenger side in the cover before installing the plate. You can't get the front 2 bolts in once the cover is in place.
We pre primed the oil galleys and the HPOP to save the batteries and starter on startup.
Total time under head app. 17 hours and $90.00. Truck started with minimal cranking and now runs good once the air purged out of the HPOP system.
Les
1 1/2 hours to get to the turbo for removal then disaster strikes. The third bolt down bolt (in the back) strips the head on the bolt. Tried several different stripped head bolt removal devices and none worked.
Dropped the down pipe for easier access to the bolt (1 hour). Ended up cutting the head off with a cut off disc. Worked great. Total time from start to turbo on ground 4 hours.
Removed the IPR and HPOP cover (8 ea 8 mm head bolts three of which are under the egr tube on the passenger side (tight but workable) and 2 ea in back holding exhaust heat shield. The cover requires some inventive manuvering to get out(more on this during reassembly). Removed the HPOP and checked the quick disconnect. Not cracked (1 hour). So we continued on to the next item.
Removed the valve covers (2 bolts on passenger side next to the heater box difficult to get to but doable) and the HP oil galleys (logs?) 1 hour. Checked o rings on stand pipes (back end of engine) and they were good. NOTE: Remove 10 mm head allen head plug before removing oil galley and it will come out easily.
Removed dummy plug on top front side of oil galley to check O rings. AHA!!!
Found the bottom o ring on each dummy plug deteriated and burnt looking. This allowed oil to go back to the crankcase when hot instead of maintaining oil pressure.
Spent $90.00 at dealer for needed o rings and upgrade for HPOP quick disconnect.(the upgrade eleminates the quick connect and becomes a solid unit that screws into the HPOP).
Started reassembly in reverse order.
NOTE:
When you get to the HPOP cover plate, cut off the taller exhaust shield tab on the passenger side and the plate goes on with minimal effort(Install the three bolts under the EGR tube on the passenger side in the cover before installing the plate. You can't get the front 2 bolts in once the cover is in place.
We pre primed the oil galleys and the HPOP to save the batteries and starter on startup.
Total time under head app. 17 hours and $90.00. Truck started with minimal cranking and now runs good once the air purged out of the HPOP system.
Les
