I've been working on my trucks starting issue for a few months, off and on. I've replaced a leaking rear fuel tank, the fuel pickups, all the fuel lines, installed an electric lift pump, new orings on the injectors, rebuilt injectors, rebuilt i/p...fixed on my fuel filter heater connection...I'm starting to wonder if the rebuilt injectors I bought are substandard. I bought them online, the same place I got the ip. It didn't work and I had to return it, and get one locally...for alot more money. After it sits a coupla' hours, it takes quit a bit of cranking. I usually crank it for 5-10 secs...hit the manual glow plugs for 10 secs, then it often cranks and fires within the next 5-10 secs [sometimes, takes another gp cycle]. After it's warmed up, it usually starts nicely. I put a hand operated vaccuum pump on the place where the return line leaves the engine and it holds 10" of hg, as long as I watched it [several minutes]. When I first got it, it would start real well. I would let the glow plug controller cycle, when the wts lt would go off, crank-boom. I want that back. I've replaced the starter, new batteries...It's damned frustrating...what do y'all think? Maybe I didn't get a good seal on the injector to head connection?...or the injectors are just poorly calibrated...I don't know. It doesn't seem like I have a fuel supply issue...but, there's still the "replace the fuel filter assy" option.

 

It sounds like you may have solved the air intrusion problems, and now the glow plugs may not be working correctly. Have you tested them with an ohm meter or test light? Are they getting voltage? Any other symptoms like a lot of smoke once it starts?

I donno about the injectors...

Don't crank the starter for more than 20 seconds without waiting 2 minutes...otherwise the starter can overheat and fail.

 

I've checked them with an ohm meter...haven't checked voltage...but, they worked on automatic, but I wanted manual control so they wouldn't cycle after engine start as I had a chevy that burned out heaters until I went manual.

 

I will send you the GP controller test info. Just click on my name and email me... Please use subject: GP controller info. If it worked before put it back to OEM..... What GPs do you have in it.........I hope not Chumpion or Autolite....... only Beru/Motorcraft from Azone recommended as they were OEM.