The old 6.9 has been having problems the last couple days on cold starts. It will start fine, run 4-5 seconds and die. I will crank it over for a good 15 seconds but it won't even catch or attempt to start. I'll turn the key off and let the glow plug timer recycle itself so they'll turn on for a long time before I start it next time but it still won't start. After three or four times of doing this it'll finally start with a lot of difficulty and run rough for 10 seconds or so before it smooths out. Once it's warmed up it starts immediately and runs great. It will do this no matter the outside temps, it was 70deg out and had been sitting in the sun all day, same thing. Please help as this is soon to become my daily driver as the celica gets a new rear suspension.

 

Most common causes are fuel return tees leaking and bad glo plugs.You need to check those out 1st.Do a search and you will find lots of instructions on how to R&R them.If you get into any problems post back,keep us posted on your progress as it could help someone else that is having similar troubles.

 

fuel return lines and injector return O-rings are new on the passenger side of the engine and I have the O-rings for the other side but haven't had time to install them yet. If you think that could be causing it I'll be doing that sooner rather than later and if it fixes the problem I'll definitely let everyone know. The glow plugs are relatively new along with a new controller, but I want to check the wiring and make sure all the connections are tight. Thanks for the reply.

 

You could also be pulling air through your fuel/water separator. Try plugging the drain hose and see if it stops. If for some reason you need to drain water, you can remove the bolt that you plugged the hose with. Down here in the south, I have by-passed my separators with no ill effects.

 

I have pretty much the same problem, but the one thing that's happening to me that no one has mentioned is that when my 6.9 dies, the fuel filter has only about an inch of fuel in it. Should the filter always remain completely full. I can feel it with fuel and it starts. But after setting for an hour and a half, it is back to only an inch of fuel in the filter. Help

 

the filter should stay full,you have an air leak.check your return lines and o-rings,it may be leaking/sucking air but not laeking fuel