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

 

Start with filter, definitely.
Also, make sure your fuel pump is running during cranking. I made that mistake and it took about 3 years running perfectly to manifest its self and I was stuck.

 

I think you need some clear line some where in the system, Change the filter my guess is if you fixed everything including the O rings in the fuel lines yes the ones on all the quick release pieces or just cut off and put rubber on that your electric pump is bad or the IP is dieing a slow death.

But the clear line will tell ya quick what's happining.

 

I am going to change the fuel filter this morning. The e-pump is a carrier and was new a month ago. I also can see the the fuel running through the clear bowl. The IP and Injectors are a brand new rebuild from Type4. I will try cracking a couple of injectors too.

I will double check my wiring to make sure I am getting the 12v signal during cranking. It is weird that it ran perfect and then all of a sudden it won't even start.

 

Got it running. Replaced the fuel filter and it fired right up. Old filter was only half full. Thinking that it was clogged enough that it was all coming back to in the return lines. Also found a fuel leak. It is coming from the back top of the fuel filter housing where it looks like a sensor wire is attached. I'll start another thread on how to fix it, but this could be why my mileage isnt where I want it.