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Went out to the dirt drags today (nothing else planned) parked the truck in the field and caught a ride into town to check out some of the festivities. Came back probably 30-45min later and went to start the truck and got the eternal crank. Checked FSS found to still be working (no surprise there since it was working fine when I shut it off) so cracked a couple injector lines. Got fuel there so shut the lines and she fired right up. Far as I can tell I somehow got air in the fuel lines, but have NEVER had a problem all summer (had a leaking fuel heater last fall but fine since then) had plenty of fuel in freshly filled tanks, fairly new mech lift pump and no signs of leakage. So how the heck did I end up with air in the lines (has worked perfectly ever since this morning)
Brand new IP, in both cases it had been off for probably 30-45min and its restarted flawlessly when its been off for 5min (when hot) all the way up to over night since the first time.
So ya pretty sure it wasn't the hot ip problem, especially since in both cases the IP was still hot when it did start (probably spent 5-10min to get it running in both cases)
Did both times happen during the heat of the day.
My thinking is that you have a seal in the fuel system starting to go or your lift pump is getting weak, When you shut it off hot in the middle of the day all the heat opens up some little crack in a seal to let air in.
I would start with the supply line to the ip, because it was the last thing you messed with.
That I could belive, especially since Ive had intermittent issues with the rear tank leaking (brand new as well), the biggest oddball thing for me is the second time around I was getting fuel at the injectors (cracked them and they sprayed) but it still wouldn't start until I swapped tanks, only thing I can figure is there was just enough fuel to squirt with air pressure in the lines.
I had a psd that would run great, but die going down the road about once a day. That was caused by the seals in the quick connect at the sending unit. maybe you could have something simlar going on.To test mine I wiggled the lines going to the tank while it was running.