Ok folks, forgive me if I miss anything or mess something up in here cause I'm new!

I have In 86 F250 6.9l that WILL NOT start for anything. I have been arguing with it off and on for the last few years with no luck. When I bought it, it was running and driving but dumping plenty of white, fuel rich smoke. I assumed it was my IP finally going out, which it did finally. When it died I was 46 miles from home and taking it easy (nothing over 60 mph), and it started to act like it wasn't getting fuel. When nosed down hill, I couldn't pop the clutch and keep the truck running, but if I popped the clutch just as it tipped nose-up on a hill, it would roar to life and take off. It made it a few miles choking, then gave up. I finally got around to changing the IP out (talk about pricey!) and still had no start.

Now I'll just skip to what eat has been replaced/done:
-all new plugs
-new electric fuel pump to replace mechanical lift pump
-new starter (old one was stolen)
-new fuel lines on top of block
-oil/oil filter change
-fuel filter changed repeatedly
-tried new batteries
-new voltage regulator

I don't think I'm forgetting any parts that went in. I know the block is free and will turn over. Half the time the starter or starter relay will clunk once when turning the key, but nothing else. Half the time the glow plugs will not cycle (they used to cycle every time after it died originally). We have even tried pull starting it, which resulted in some coughing smoke out of the tail pipe, then nothing.

if anyone has any suggestions, it would be great! Half the time it's like the truck will want to start, even try to cough a couple times, then the rest of the time you'd think you were working on a rock.

I love this truck, but it's either going to be the end of me or will meet a very ugly death because it's driving me insane. I've dug up any info I can on the truck, asked anyone I could, but I'm still S.O.L.

Half the people around here don't know anything about this beast and the other half will argue that it doesn't exist.

Someone save me!!

 

did you Replace the injectors when you replaced the IP ?

Generally the IP will not Over fuel but leaking injectors sure will.

Now when you replaced the IP did you have the IP Gear housing off ?

IF so the First thing I would do is check the timing.

on the starter not working and the Relay just clunks this is often Burned contacts in the starter relay..

Not all electric pumps are created equal, are you sure you have good fuel flow to the IP ?

You have a lot going on right now and it difficult to give a single answer.

 

Injectors were not replaced with the IP, but they were throughly inspected/cleaned when fuel line was replaced. They are in great shape, almost like new.

On the pump overfueling, I bought the truck sight unseen and was told it had a possible impending IP failure. When I tore it down before replacing it, there were several internal pieces damaged. The IP had been rebuilt once and "upgraded" due to a flaw in the original pump?

When I pulled the IP, all I removed was the fill neck to access the three bolts on the front. I was following the repair/rebuild manual for the IP. Nothing was turned over or moved while the IP was out of the truck. The new pump is brand spanking new! 😁

The starter relay was replaced, and the new one had the same problem. Things are a little dusty under the hood, but nothing horrible and I have been all over the engine (literally sitting on the radiator support to reach the engine), I haven't found anything melted, scorched, roasted, nada.

I did my research before deleting the mechanical pump and putting the electric in. It's strong enough, but not overkill either. I have been able to bleed fuel lines and get fuel all the way with the new IP.

The steering column is what you would expect in a farm truck... broken, tilt slips all the way down, touch the turn signal and the wipers go.. The key was locked in the ignition until after the truck died. Nothing with the column changed or happened until after, so I'm not sure it's related.

When the truck was running, it was being used for fence work and spent many hours idling, in all temperatures. Besides barely smoking, it never missed a beat when idling. I had one incident with the coolant shortly after getting it. I ran 3 miles to town (30 mph the whole way), parked it for 4 hours and then went home for lunch. 2 miles in, it starts letting out this horrid howl-like-a-banshee noise for 3-4 seconds and dumped coolant from the reservoir. The truck never even got fully warmed up and it was a mild day. Stayed running, and besides the noise/dumping coolant, it never did anything close again.

Call me crazy, I know! This truck had me hooked from day one and I just can't give up on it yet.

 

That's crazy that someone stole your starter! The top bolt is a bear to get to. I'd be asking your buddies with IDI trucks if they have any "NEW" spare starters. They weigh a ton but probably can't be worth much as scrap.

I'd say double check your fuel delivery. You mentioned you bled the injectors, but did you depress the schraeder valve at the fuel filter and get a solid stream of fuel? Low fuel level in the fuel filter after driving the truck is an indication of air intrusion.

Since you just installed a new IP you might also try advancing (IP toward passenger's side) or retarding (IP toward driver's side) the IP to see if you can get the engine started.

Good luck! ​​​​​​​

 

Got a harbor freight near ya?

They have a diesel compression tester for $30 that does the job. At this point of it being a bear to start, and the fact it ran for how knows how long white smoking the rings/cylinders could be shot..

For $30 and some gas money I think it's a wise investment before you invest any more on a motor that might not be any good anymore.

If it has enough compression it sounds like you have a fuel supply issue.

Have you tried drag starting it?

 

Check that you're getting a solid 12 volts to your Fuel Shutoff Solenoid. Had that problem before.