6.9 died on the freeway and I can't get it started again

[Tk83]

I was driving on the freeway after filling up with fuel about 50 miles before, and the truck started running rough then died within about 30 seconds. I thought it was probably bad fuel and did not have any extra fuel filters so I had it towed home. I changed the fuel filter on the engine and tried starting it with an electric fuel pump drawing from a can of new diesel (from a different station) hooked right to the line that goes to the fuel filter and it started for a minute and I shut it off because the mechanical pump was still pumping fuel out and making a mess, but now I cant get it started again.

I had to take the whole fuel system apart when I got the truck to replace the lines, rear tank, etc so I do have some idea of what it takes to get the air out, but I think something else is wrong.

I'm really running out of ideas of what to try, but I would like to at least know what happened before listing it for sale and saying "died on the freeway, unknown engine issue". If it really did have a major failure that's just the risk of old vehicles, but I don't want to give up and sell it for near nothing just because I wasn't smart enough to find the problem but it was actually something simple.

My best guesses would be either that it's way harder to get the air out of the lines than I'm expecting and I was just lucky before, or that the injection pump has failed, but I really have no idea.

 

[Jesus Freak]

It does take a while to bleed the system. If you got a Manuel transmission and a buddy to pull you around it takes like 300yds to prime the system and its easier on your starter, batteries, and, patience......other than that if your mechanical pump is pumping, and it runs fine after you finally crank it up, the IP could be wore out and work fine until it gets really warm and it starts "heat soaking", then it has to cool off to work again.......

 

[IDIBRONCO]

Why don't you try running the engine off of a can again? This time have everything hooked up and see how long it will run. If it runs for 5 minutes or so without any problems, it's probably drawing in air before the lift pump.

 

[Clb]

Feed the mechanical pump from a fresh can of fuel.

Check the 12v to the i.p. (especially the fuel valve.)

If it's not hot it won't run.
Then chase fuel path rearward from i.p. for blockage...

 

[Tk83]

I did try running it from a line into a can going right into the mechanical pump and it would not start, even after using an oil extractor to suck fuel all the way up to the filter. I thought the mechanical lift pump may have failed and tried to change it, but I could not fit my hand past the pump to get the rearward bolt in. I decided that since it started from the electric pump I would worry about that later, if I can't get it with the vaccum pump and bracket removed either convert to a permanent electric pump or have it towed to a shop to get someone to put that bolt in.

I'm going to try running power right to the shutoff valve on the injection pump and try again with the electric pump from a can of fuel and crack the injector lines loose to see if any fuel comes out. If not, I'm going to have to assume the injection pump failed unless there is something else I might be missing? It was running fine until this happened but it had sat for years before I got it so maybe that damaged the pump. I have driven it thousands of miles before that will no issues though.

 

[Brian VT]

You should be able to hear the FSS valve open and close when you turn the key on and off.

 

[IDIBRONCO]

I did try running it from a line into a can going right into the mechanical pump and it would not start, even after using an oil extractor to suck fuel all the way up to the filter. I thought the mechanical lift pump may have failed and tried to change it,

tried starting it with an electric fuel pump drawing from a can of new diesel (from a different station) hooked right to the line that goes to the fuel filter and it started for a minute and I shut it off because the mechanical pump was still pumping fuel out and making a mess,

It seems like you're saying two different things here. Could you please clarify?
For mechanical lift pump removal, I like to disconnect the hard line that goes to the fuel filter and the ground cable plus what else may be attached to it right in front of the pump. Maybe even removing the vacuum pump too. This makes for MUCH easier access.

 

[IDIBRONCO]

You should be able to hear the FSS valve open and close when you turn the key on and off.

And you can feel it if you place your hand on top of the IP while you're experimenting. People who don't hear very well or people in noisy environments might not be able to hear the click.

 

[Clb]

Bottom of para. 1 in post #1, it started on the e pump, but the mechanical pump was puking...
Was it just residual or was it looking like it was working properly?
If it's now not, ( post#5) that's going to be a "Let's dive deep into the thing" deal.
As for the rear bolt, at home with everything you have foe extension, wobble,universals ect.....
Give it your best shot at replacement.
There's some reports that guys have driven off without the e pump turned on.

 

[ihc1470]

Hang you temp tank higher than the injection pump and let gravity work for testing. You can also then see what your pumps are doing as far as moving fuel. Just run a temp line into your test tank.

 

[Tk83]

When I first tried starting it with the electric pump the mechanical pump was still connected, it seemed to be pumping a normal amount of fuel, but when I tried putting the line feeding the mechanical pump into a can of fuel it would not start so I assumed it was bad (which I now think wasn't correct). I'd have to take quite a bit apart to reinstall it though, it's not the trucks fault but I get so dizzy when I lay on my back that I can't hold the bolt in the right place. I can get the end of the bolt in the hole with a socket on it but it's too crooked to thread in.

Today I tried hooking 12v to the shutoff solenoid and it did click open, then tried loosening some.of.the injector lines and started it and it actually did run, but I shut it off to try to attach the fuel can to the bumper so I could move it from where the tow truck dropped it off, and I couldn't get it started again and I ran the batteries dead cranking it.

I am admitting defeat at this point, it's beyond what I can solve myself. Does anyone know of a shop in the area between San Francisco and Sacramento where I could have it towed to have someone who actually knows about these try to fix it? Otherwise I think I'm going to have to try to sell it not running because I don't know what else to do.

 

[ihc1470]

When I first tried starting it with the electric pump the mechanical pump was still connected, it seemed to be pumping a normal amount of fuel, but when I tried putting the line feeding the mechanical pump into a can of fuel it would not start so I assumed it was bad (which I now think wasn't correct). I'd have to take quite a bit apart to reinstall it though, it's not the trucks fault but I get so dizzy when I lay on my back that I can't hold the bolt in the right place. I can get the end of the bolt in the hole with a socket on it but it's too crooked to thread in.

Today I tried hooking 12v to the shutoff solenoid and it did click open, then tried loosening some.of.the injector lines and started it and it actually did run, but I shut it off to try to attach the fuel can to the bumper so I could move it from where the tow truck dropped it off, and I couldn't get it started again and I ran the batteries dead cranking it.

I am admitting defeat at this point, it's beyond what I can solve myself. Does anyone know of a shop in the area between San Francisco and Sacramento where I could have it towed to have someone who actually knows about these try to fix it? Otherwise I think I'm going to have to try to sell it not running because I don't know what else to do.

Don't give up yet. Charge your batterys up fully. The engine needs to spin fast to start. Glow plugs work? If not does the block heater work? You need warm cylinders or it is not going to start very well. Fuel return line to tank open, if you blow air through the line you can hear it back at tank with cap off? If I am thinking of the right fuel system that pump has a return coming off top of pump correct? If so have you pulled that line to see if you have some fuel coming out? Pretty sure if that is pluged it will not start or run very well due to the wrong case pressures. Throttle to the floor while cranking? Any smoke in the exhaust?

Get your temporary fuel can above your injection pump so gravity will work for you. If every thing is clean you could even bypass the filter and go directly to the injection pump for a few minutes. If you do that I would either make the fuel coming from the tanks go into another container or through the fuel filter before I would allow it to go into the temp full can. You do not want any dirt getting into the pump.

Manual or auto transmission? If manual you might try toe starting it.

I normally do not use it, you might try a small amount of starting fluid just make sure you have the glow plugs disabled first.

 

[Clb]

Any Ag shops near you?
Any farming companies?
Any old tractor guys around?
Last ditch, grape growers.

 

[Tk83]

I can try pulling the return line, I was able to loosen the lines on the injectors and get some fuel to come out. The batteries need replacing, I can only get about 5 minutes of trying to start it before having to charge them for a few hours, I don't want to buy batteries when I don't know if I will be able to get the truck fixed though, because I doubt I'd get more over double the cost of a set of batteries for it not running. I did get some white smoke out the exhaust but definitely not enough that the injectors seem to be working as normal. I have gotten it to start a couple times and run for a few minutes, but if I shut it off or put it in gear it dies or won't start again for more than about 10 seconds then it will crank until the batteries die with no smoke in the exhaust or anything. I have tried hooking 12v right to the shutoff solenoid and it does click, but doesn't have any effect on the other issues.

 

[ihc1470]

Silly question maybe, does this truck have one or two fuel tanks and are both working. Are they both full or close to it with fuel. Would not be the first time that someone got on an empty tank especially if the gauge does not work. I know you said you fueled 50 miles ago. Not sure if that would be both tanks if equipped or if a few gallons to get home.