I’ve done all of the trouble shooting I can do and am at a loss. The FSS is good I think, solid clicking sound. I took the top off and wiggled a few things and put it back on. Nothing.

there is fuel to the pump, just no fuel from the pump.

 

Did you use a multimeter to measure 12 VDC at the FSS?

 

yes, 12VDC

 

Just found this algae buildup on the FSS, what does it mean for the pump?

 

Picture of the inside

 

Also, there is no power to the connection closest to the cab, will that keep it from operating?

 

I'm pretty sure the only power the IP needs is the 12v to operate the FSS--in an emergency you can run a jumper wire from the battery straight to the IP. If the IP has been sitting a long time it could be seized. I knew someone who's truck was down for a while with heads getting rebuilt and other problems and when everything was reassembled the formerly working IP had seized. The guy had fuel to the IP, FSS was functioning, but nothing to the injectors--new IP and everything worked fine.

 

any way to know if it’s seized.

Could it be a fuel lift pump issue? The one I have is rated a max of 3.5psi and I have an RD2 80cc pump in it.

 

I'd be surprised if it was a lift pump issue. If you have fuel to the pump then it ought to at least start. Have you checked to see if you have full flow of fuel out of the filter or the line feeding the IP? I know a stock IP will pull enough fuel to run without a lift pump. I've accidentally turned off my Facet lift pump and driven quite a few miles with just the IP sucking fuel. That algae does not look good.

 

You could always remove the IP and soak it in ATF. It would be a PITA to remove all the injection lines but if all else fails it may be your last resort. Make sure you don't remove the IP timing gear though. If you just remove the IP there's only 1 way it can go back on so you can't mess up the timing too bad. Good luck.

 

You're going to need something that will kill the algae. internet search: Bio Kleen Diesel Fuel Biocide

Maybe try taking your IP cover back off, soaking up, or sucking out, all the fuel in there and then filling it with that. Your fuel filter might be full of it too and tanks. So be sure to change the filter and add some to the tanks. Anyway, after filling the IP and making sure you place the cover back on correctly so that if/when it does start, it doesn't runaway, then crank for 15 seconds or so and hopefully it pushes some through the IP. Then let it set overnight if didn't start, and then try doing the same thing the next day. Maybe it will eventually clean out enough to fire and run and if it does, it will hopefully clean the rest out over time with more in the tank?

I don't know if this will work or if it's hopeful thinking, as I've never run into this issue before. Just something I'd try unless someone knows this wont work and tells you not to bother. It seems think a reasonable thing to try to me, before removing the IP from the truck and attempting to disassemble it and clean it.

Well, it says 1 ounce of the stuff treats 20 gallons, so perhaps don't try draining the IP. Just enough to add a teaspoon or so to the fuel in there, let it set there for.... how long? Then try cranking? I've only guesses.

 

Just to close out this thread, we fixed it. Took off the top of the IP and the actual spring thing near the passenger side was completely seized up, so when the FSS solenoid was moving out of the way, the spring still wasn’t moving and allowing fuel through. I cleaned it with brake clean, sucked out all of the gunk and brake clean, and started bleeding the lines.

got it timed to 8.5 degrees and we are running and roaring. Thanks for all the help!

 

Nice. I would get some Biocide in the system to make sure all the algae is killed still though. Pour some right in the tanks. You don't want it growing back.

 

You could also remove the fuel filter, fill it with ATF or your fuel additive of choice. Then start and run the truck for a minute or so. After that, turn the truck off and let it sit overnight. This will give the ATF a chance to clean everything inside the IP.

 

I did add biocide to the tanks and the filter. She is running decently smooth, on to the next problem!

just for other people’s future reference, I’m going to add a picture of the linkage that was seized up. Just had to get in there and exercise it.