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I have a 1994 7.3 turbo idi that has been having some hard start issues. It will always start but its real cranky and when it does start it will run kinda rough and really "clacky" unitl it warms up then it runs perfectly(I have verified the glow plugs work right and it has 8 new Motorcraft in it). I put a piece of clear tube on the return line hose that goes to the injection pump and it seems like air is coming in through the pump. And now the fuel light comes on when it's cranking. Not really sure what this means, so any help would be greatly appreciated. I have looked for leaks and there are none that I can see, there is a little diesel splattered on the firewall but I can't figure out where it is coming from?
Could be coming from the return line that goes back to the selector valve/tanks. Take a flashlight and look down the back of the engine on the drivers side to see if anything is wet. It is a piece of 5/16 hose that connects to the plastic fuel line. When mine let go it was further down the hose and was dumping fuel onto the exhaust cross pipe
Might be time for fuel line olives on the feed line from the filter housing to the pump.
If I understand correctly you put the clear piece on the return outlet of the pump itself where it has that short rubber line.
If that's the case most likely you have air intrusion from the supply side.
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