Fuel issue has me stumped/stranded

[jayro88]

Okay, so I am stumped and need some help. The short version is that I started having a air intrusion like symptoms a a couple of days ago and now my van won't start. Like I drove it to pick up my kids up at school. Parked it, walked in got the kids and then was stranded in the parking lot.

So the long version with all the details to help diagnose the issue:
1. Vehicle info...'88 E250 7.3 NA. In the last month I did the following to the fuel system. E-pump, IP/Injectors/return lines, sender and fixed pick-ups. This was completed over the course of about a month and was completed a month ago. After the upgrades/maintenance the van ran great and started better than it ever had. Like fired on the second turn over even when the temp dropped in the 40's. Prior to this maintenance the van required some cranking prior to starting.

2. The issue history. About 4-5 days ago the van started to show some air intrusion symptoms (even though I had the e-pump). It would fire immediately, run for 20 seconds and then die. Then it would take a bit of time letting the pump run and cranking for it to start again. The first couple of days it was just the first start in the morning. Then it was only if there was 7-8 hours in between. Then today it did it with 3 hours in between and then 20 minutes and won't fire up or even try and catch.

3. So I thought maybe fixing the pick-ups sucked up some junks and messed up my selector valve. Took the lines off and verified that all was clear and working properly. I checked the schrader valve on the fuel filter and verified that there was plenty of flow up to the filter head.

So what do you think?

The only other thing that I can think of that isn't new is my fuel filter. I purchased a new one and will be replacing it tomorrow. I purchased the vehicle last Oct and it was on it when I got it. Is it possible that the filter would cause these symptoms? If not, what are my other possibilities?

Thanks

 

[Brad S.]

Maybe your fuel line from the filter to the IP, check the olives., and or read this one.
http://www.oilburners.net/forums/showthread.php?58566-Fuel-leak-help&highlight=fuel+line+olives
Don't want to try to copy the pics.

 

[rattleonby]

How old is the fuel filter? If you dont know then definately replace it to take it out of the equation. There should be a generous squirt or stream out of your shraeder valve at the filter housing...more than a trickle. If not then I would pop the feed line off at the pump and put a hose in a gallon container of diesel to make sure its not a selector valve or a bad shower head pickup.

 

[icanfixall]

Any wet places on the feed or retun lines is a leak. Mostly it will suck in air as the fuel drains back to the tanks. The fuel is heavier than the air so it gets sucked in easier than it flows out. Try tightening up the filter to injection pump feed line. Thats where there are 2 olives sealing both ends of the line. They are 5/16 in size and any good injection pump repair shop has them. The other one is 3/8 size and its located on the lift pump to filter inlet side. Just look for the brass nut on that line. Many times they are tuff to remove cause they harden up. Just soak them in brake fluid overnite. Then a dental pick gets them out. Or a propane or map gas torch will burn them out too but that can get real hot and smelly.

 

[rockbender]

You recently did the e-pump conversion and bypassed your mechanical pump, right? There may be a possibility that the e-pump doesn't have the check valve like the mechanical lift pump did and if the check valve in the tanks is bad it could easily be draining back. Now... why is it happening hot and not cold? Is your e-pump hooked up to your glow plug circuit to prime the cold engine?

I haven't had the hard hot start, but have had all the kids and picnic loaded up to a no-start condition at the house before. No fun city. In each case, I've been able to get things started again by cracking injectors while turning it over... so classic air intrusion.

 

[jayro88]

I bypassed the the mechanical pump...ran a new supply line directly to the filter head from the pump. I am going to change fuel filter this morning and will try cracking an injector if the filter doesn't work. the e-pump is a Carrier that has a built in check valve (I believe).

It's just weird that it ran absolutely perfect with the new set up for the past month and then all of a sudden nothing......plus its sitting in my kids school parking lot which makes it a pain to work on. Thanks

 

[gandalf]

You said that you have recently replaced the IP and the injectors. Nobody has asked an obvious question. Where did you get the replacement IP? Not all rebuilt IPs are created equal. Some will last for years, but others aren't worth the time it takes to install.

Once you've confirmed that the fuel filter has good flow, try removing the return line from the top of the IP. Run a temp line from the IP return into a small container while you crank the engine. You should get fuel into that container.

 

[jayro88]

Got it fired up. I pulled the old filter and found that it was only half full. Think it was clogged up enough that it wasn't filling like it should. I did also find a fuel leak coming from a sensor on the top back of the where you attach the fuel filter. I started a new thread for that issue along with a pic. Thanks

 

[freebird01]

i dont know if the filter head is the same as a pickup one...if it is i have one or two extra i could let go of one if you need one

 

[jayro88]

i dont know if the filter head is the same as a pickup one...if it is i have one or two extra i could let go of one if you need one

I appreciate the offer. I will look into it, but I think the van is different than the pick up. Still debating on weather to try replacing the o-ring to stop the leak or just remove the heater and plug it. Either one is the same amount of work, just don't want it to start leaking again and have to repeat it. As much as I like the IDI engine it is not that comfortable to lay on.

Are there any other IDI's running around the Ft Wayne area.....I really haven't seen any.

 

[freebird01]

i pass a nice reg cab dually in hicksville about every other day... ive seen one maybe two but your right not many...