Hello to all. First time poster. Picked up a '96 dually that had been sitting for two years. 183k miles. Family went to start it to move it in driveway to sell it. Started up and ran for 2-3 minutes then died. Wouldn't start after that. We bought it. Fuel filter very dirty and bowl was empty. Changed filter and filled bowl and it ran very briefly. Fuel pump not pumping. Replaced fuel pump, new fuel heater, rebuilt fuel regulator, brand new batteries. Just cranks. The truck has been modified. Bigger turbo, exhaust, compression brake. When we had the regulator apart we saw that there was no sensor. The hole was plugged with a set screw. There was also no ball behind the screen. WTS light is on. Glow plug relay is cycling. Ohmed all fuses. All good. Replaced CPS with a known good one. Starter turns a little slower than the other powerstrokes we've had. Unplugged ICP. no difference. None of the others we've had have been modified so this is new territory for me. Wife is threatening to shoot it. People we bought it from are no help as it was their grandpa's truck and he passed away. Thanks in advance for your help.

 

Have you measured resistance accross the GPR, it will buzz and sound like its working, even though its not getting enough volts to the glowplugs.

 

Did you TEST the fuel pump ops again after replacing it?

Does the tach move when you crank the engine?

 

I swapped out the GP relay with a known good one. Yes I checked fuel ops after putting it back together. The tach moves while turning it over. The oil idiot guage comes up while cranking. I plugged the block heater in for about 6 hours before trying. I read various boards trying to learn more about this. I have an Innova 3130 code reader but it won't communicate with the PCM. Several people have posted that most code readers won't work on a Powerstroke. The code reader is good; checked it on a couple of cars to verify that. l guess I've been lucky with my other trucks because the only things that went out were starters and alternators. Checked the fuse for the PCM. It's good. Pulled the connectors off of the IDM and PCM to check for water, dirt, crud. They are good. What readers work for the Powerstroke?

 

* Conventional old-school - Snap-ON MT2500 with the proper cables and K2(a) key. Best bet is eBay
* Dash gauge format - Aeroforce Interceptor
* Software / Windows - AutoEnginuity, bundled with an ELM chip/cable and the "Ford Enhanced" features
* Newest contender - Torque Pro / Car Gauge Pro apps, with bluetooth ELM and an Android device (Torque claims their app now works with a USB ELM) - requires some manual setup; there's an EXTENSIVE thread on the subject on "the Nation"

Are you seeing any smoke from the tailpipe as you crank it?

 

I'd check the HPOP reservoir to make sure it hasn't ran dry. Oil should be about an inch below the top.

 

Checked the HPOP. It's full. No smoke out of the exhaust. Ohmed all of the cables, cleaned grounds, checked all connections just because it has been sitting for a couple of years. Going to change the oil too because it is pretty black. The fuel is fresh. Clear in the filter. Going to get the Android app and dongle for it to try to get some codes out of it. The confusing thing is it fired and ran briefly when we filled the filter.

 

I would recommend a GOOD read of that thread over on the Nation, about the Android / Torque solution. It's a LONG thread, and I don't know if they've cracked the nut of obtaining trouble codes. MOST of the discussion is about real-time sensor data.

 

OK. Finally able to get back to working on the truck. Ordered the bluetooth, have Torque and CarGauge apps. Standard codes of 603 and 470 are there. Cargauge app has a Buzz test. Passed. Tested IPR. 14.6 sitting there and 54.something during cranking. ICP was 108 sitting and 3217 during cranking. KOEO test passed. Still no start. No smoke from tail pipe during cranking. Tach moves. Oil idiot gauge comes up while cranking.

 

https://docs.google.com/file/d/0Byb4...VGc/edit?pli=1

 

It runs. Watched a YouTube video of someone who hooked up an EFI fuel pump on a truck that had sat for a long time like ours. Also sprayed a healthy dose of WD40 into the intake. Cranked it for about 30 seconds and it fired like we just shut it off. Disconnected the EFI pump and hooked it back up the mechanical and haven't had a bit of problem since. Thanks to all of the people who offered help.