89 F350 7.3 IDI 5spd
New International GP controller
New Ford GP wiring harness
New Beru GP's
New Batteries
New Starter

Trouble Starting!
I checked the voltage at the glow plug and it's only 9.6 volts.
Another thing I also noticed, prior to replacing these parts the "wait to start light" would go out at the same time you could hear the controller cycling, now the light goes out and it's several seconds (maybe 5 or more) and then the controller starts cycling. This may be a separate issue as I think the 9.6 volts is the bigger problem. What's causing the low voltage?

 

Did you read the stickies at the top of the forum??

How is the connector on the passenger firewall where the glowplug harness connects to the rest of the wiring? Especially the 2 larger yellow wires that run through there (I think thats the right color). How do the battery connectors look?
And of the not so obvious, are you sure the new batteries are fully charged?

How fast is the engine turning over? and what do you mean by trouble starting?

How are the return lines? Could be air intrusion, this has also been covered a million times.

 

There is a normal voltage drop in the wiring going to the GP's, from what I understand. I cant remember where I read this, maybe the sticky, but I dont think the 9.6v is a problem.

 

good glow plug diag info in this thread.

https://www.ford-trucks.com/forums/1...low-plugs.html

 

That voltage sounds OK.
Depending on the weather, if it's cold...the plugs may cycle a few times after the light goes out and the truck has started. (click, click, click)

 

Sounds like the GP system is functioning correctly. Could timing have anything to do with it? I had new injectors and a new injection pump installed on this truck last year, and since installed I've noticed the fuel mileage is worse and it smokes a lot more. Another thing that surprised me was after these parts were installed there was no noticable power improvement.

 

what color smoke?
who rebuild the ip? is your idi n/a or turbocharged? what ip number was installed? did you go with new or used injectors? what code?
did you have the timing set properly?

 

IP & Injectors are both "NEW" from pensacola diesel. Suppose to be stock replacements, not sure what number / letter they are. (I seem to remember BB on the injectors???) The smoke color is white (unburnt fuel) when starting. When I'm driving, the smoke is black. This is a NA 7.3 IDI (considering putting a Banks Turbo on it however that's another story). I'm pretty sure the guy who installed the pump does not have sophisticated timing tools and simply set it by "ear". Prior to adding these parts I got 20-21 mpg and it had more power. I haven't checked the fuel mileage however it's significantly worse and starting the engine is just as difficult as before all of this work was done.

The original reason I had the cylinder heads removed and rebuilt was to remove two broken glow plugs. When I bought the truck two glow plugs were snapped off inside one of the heads and one even had a broken easy out. Anyway while they were off and at the machine shop I figured it was the perfect time for a valve job. One thing lead to another and I ended up with pretty much an new engine however the orignal problem still exists (hard to start). Seems like I spent the money, the new parts are there they simply need to be adjusted correctly and everything should be fine.

 

not much good ever comes from the cheap parts found at pensacola diesel.
this is explains why you were better off before.hopefully you saved your old parts.

you may get lucky,who knows lol.
when you first start the truck,how long does it take the white smoke to clear up? what are the current temps? and roughly describe how large the white cloud is?
when the engine is fully warm,do you have a smooth idle at all times?
look at your receipt.try to see if you bought new or reman injectors from them.

the fuel is set too high.this is the reason for the black smoke,loss of performance and reduced fuel economy.
turn the fuel in the ip down a flat.this will clear up some black smoke,and greatly increase throttle response and economy.

undue a timing by ear mistake.
look at the timing marks on the ip.approx how straight up and down does the ip set on the engine?

when your close,you'll be able to go to a steep hill about 200' long,hold WOT and gain speed the whole way,with a strong pull of torque in the seat of your pants the whole way up without seeing any smoke in the rear view.yes,even as n/a.
then your close if not right on the money,and go turn things up from there if you wish.

 

Apparently opinions vary as I was told the exact opposite!

 

they have a poor reputation overall on many diesel sites.
however,iv only first hand experience with their crappy injector install kits.
many,many people full of regrets buying from there if you search.

 

I was wrong! The injection pump came from UHAUL TRUCK PARTS (assume it was a rebuilt unit) and the injectors were from Pensacola. These were new injectors brand name DELPHI.

 

The old injection pump number was STANADYNE DB2831.
The old injectors were BB.

 

only a few had issues with pumps that came out of the u-haul inventory clear out ebay sale.mines still working great (reman was done by IFS.) like yours,mine came with the fuel turned up too high,for my n/a engine.it blew a little black smoke on the hills and the peddle felt like mush after 1/2 throttle,with the last 3/4 of the throttle simply feeling blank.turned it down a bit and she was running clear again,and had it's power back.i remember for the few days until i could get to it,i would hold WOT like i used to with old ip,but as i let up the air/fuel ratio was way better and id be gaining speed as i let up lmao.
new BB codes should be good.could you answer a few questions from post#9?
is it safe to say,you didn't test the new set of injectors before install?

 

I took the truck to a local shop. Hopfully they can figure it out. I've had "HARD START" issues as long as I've owned this truck and I'm tired of buying parts! I just don't get it, if the test light indicates ALL of the BERU glow plugs are good (one lead on battery the other on the GP connector), and the voltage reading @ the connection point on the wiring harness is 9.6 volts, why is it hard to start??????

I called and told them about the possibility of the fuel setting being incorrect and they should check it. Could possible be the source of the smoke???