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I have a 1991 7.3L. The batteries have been replaced about 4 weeks ago, just had the alternator tested and it is fine. The starter is about 9 months old and after I driver it about 30 miles shut it off for 5 min. it has a hard time trying to start seems like there is not enough juice to crank up it turns over but won’t do anything. I have to turn the key wait for the GP light then try it again. I have to do this about 3 times and finally it will start.
If it starts up normal cold, and only has a problem when its hot, it sounds like the IP is getting heat locked. next time it has a hard time starting poor some water over the head on the pump and see if it fires right up
Not to insult, but I would steer clear of dumping water over a warm or hot injection pump. Because of the very close tolerances in the operating components of the ip, any immediate change in temperature can severely affect the life and function of the pump. What I would do is pull the pump off, and have it checked out at a Diesel shop. But, that's not to say that it's your problem. To tell you the truth, in my years working on John Deere and Detroit Diesel engines, I have never seen a hard-starting problem with a warm engine, except when they are due for an overhaul. Have you noticed any excessive oil leaks around the base of the heads?
If your IP pump and injectors have lots of miles on them replace the parts it will help starting. If the engine is hot you shouldn't need the GPs to start it even warm the engine should start with out GPs. How is your battery cables if they look bad they don't let the full juice hit the starter. You should have a Mitsubushi gear reduction starter to crank the IDIs over properly with 21-1 compression they take a good grunt to spin them over.
You also could have the dreaded cavitation hows your coolant level ?
You engine could be hydro locking if your loosing coolant from nowwhere that might be your problem.
Yeap try the water test. Confrim a no start then pour some water on it to bring the temp of the pump down. It should start if you can hold your fingers on it with out getting to hot. I just had this same problem with a rebuilt pump. The gentleman sent me a new pump and away we went. A ford diesel tech told me about useing water. Does not have to be real cold just luke warm is enough to bring the pump temp down.
Bob