Resurrecting a mid-'90's IDI
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Junior User
Joined: Oct 2004
Posts: 62
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From: Pine Bush, on the mtn.
Resurrecting a mid-'90's IDI
Guys,
Just started a super low mile IDI after sitting since mid-90's. All systems were closed and in good shape, but wiring harness was cut in several places......I changed that out already from bulkhead to starter solenoid.
This is what I've done so far.......
Shot WD down glow plugs prior to starting.
Blew fuel line out from front to back (no tanks in place then)
New fuel filter, filled up prior to starting........oil too
Fresh fuel
Bleed caps at injectors
Took a while of cranking to start......reved up high quick then died......tried again, finally got running (rough) with holding throttle.......injector pump was leaking on bottom (weep hole assume)......surges while idling.......white smoke.....chugs a lot....then bled the tops of injectors....now no leaking IP or very little in comparison.
I did finally get it to smooth out (slightly) after a little warm up, but haven't been able to keep running for longer than 3-4 mins.
Can any of you give me a check list to start with, so I can begin fine tuning? My guess is a blockage somewhere and a combo of air somewhere.
Any help would be greatly appreciated! This is a '92 F-Superduty that will become my 4x4 dump project.
Thanks in advance!
Just started a super low mile IDI after sitting since mid-90's. All systems were closed and in good shape, but wiring harness was cut in several places......I changed that out already from bulkhead to starter solenoid.
This is what I've done so far.......
Shot WD down glow plugs prior to starting.
Blew fuel line out from front to back (no tanks in place then)
New fuel filter, filled up prior to starting........oil too
Fresh fuel
Bleed caps at injectors
Took a while of cranking to start......reved up high quick then died......tried again, finally got running (rough) with holding throttle.......injector pump was leaking on bottom (weep hole assume)......surges while idling.......white smoke.....chugs a lot....then bled the tops of injectors....now no leaking IP or very little in comparison.
I did finally get it to smooth out (slightly) after a little warm up, but haven't been able to keep running for longer than 3-4 mins.
Can any of you give me a check list to start with, so I can begin fine tuning? My guess is a blockage somewhere and a combo of air somewhere.
Any help would be greatly appreciated! This is a '92 F-Superduty that will become my 4x4 dump project.
Thanks in advance!
Logistics Pro
Joined: Nov 2013
Posts: 3,928
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From: Mojave, Ca
Would you mind posting some pictures of your project? I'm wondering what a super-low mileage IDI looks like. 
Definitely sounds like air-intrusion. It might possibly have weathered and cracked fuel hose that is is leaking air... I ran into a similar problem on a 454 motorhome. For diagnosis, I would run a new hose from a jerry-can of diesel to the lift pump and see what happens when you start it.
Definitely sounds like air-intrusion. It might possibly have weathered and cracked fuel hose that is is leaking air... I ran into a similar problem on a 454 motorhome. For diagnosis, I would run a new hose from a jerry-can of diesel to the lift pump and see what happens when you start it.
Thread Starter
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Junior User
Joined: Oct 2004
Posts: 62
Likes: 0
From: Pine Bush, on the mtn.
I tried running from 5gal can first and wouldn't start.....then poured fuel into rear tank and hooked lines back up.
While trying to pull fuel from can, rear return lines were shooting fuel out, so I just hooked them back up and put fuel in tank.
Posting picts isn't allowed for me yet, but it's the gray'ist IDI I've ever seen!
I'll see what I can do for picts later in my album.
Thanks
While trying to pull fuel from can, rear return lines were shooting fuel out, so I just hooked them back up and put fuel in tank.
Posting picts isn't allowed for me yet, but it's the gray'ist IDI I've ever seen!
I'll see what I can do for picts later in my album.
Thanks
Posting Guru
Joined: Dec 2012
Posts: 1,065
Likes: 2
From: western washington
A blocked return line can make it die also, if you have a block heater plug that in to preheat engine, this will make starting it much easier, air intrusion usually makes it die 30-45 seconds after it starts, this air could be leaking in at the fuel heater O ring on top of fuel filter housing, allowing the filter to drain out. or you are sucking air some where between the lift pump and the tanks.
Thread Starter
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Junior User
Joined: Oct 2004
Posts: 62
Likes: 0
From: Pine Bush, on the mtn.
Update....
Changed lift pump....no real difference
Plugged in to start....a little better
Found 2 white wires loose on both sides of engine in harness.....grounds?
Realized my back tank (only one in place) pickup is damp at connectors....assume pulling air....found NOS pickup cheap enough..waiting to get, install and check.
I'm wondering if the white wires are the reason the GP & WTS (no lights in dash area) is having issues?
There were a lot of cut wires on this.....for several reasons....but I replaced the entire engine harness and was left with a white unhooked on both sides........can I just ground each?
Let me know your thoughts? Thanks and have a great holiday!
Changed lift pump....no real difference
Plugged in to start....a little better
Found 2 white wires loose on both sides of engine in harness.....grounds?
Realized my back tank (only one in place) pickup is damp at connectors....assume pulling air....found NOS pickup cheap enough..waiting to get, install and check.
I'm wondering if the white wires are the reason the GP & WTS (no lights in dash area) is having issues?
There were a lot of cut wires on this.....for several reasons....but I replaced the entire engine harness and was left with a white unhooked on both sides........can I just ground each?
Let me know your thoughts? Thanks and have a great holiday!
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