Have experienced the situation of engine dying after driving off after just starting and then not wanting to start again. The web site www.intellidog.com/dieselmann is a good site for knowledge of the fuel system issue with these trucks. Anyway here is what my mechanic did to get my rig up and running quickly and allow it to be driven back to his workshop for more detailed examination. Mechanic came to truck with electric fuel pump and small inline filter. He then bypassed the mechanical pump, the original fuel filter, blocked off the small return line to the filter which simply forces all the return fuel to go back to the tank, installed the inline filter and then the electric pump into the fuel supply line and then ran a clear reinforced plastic hose from the electric pump direct to the injector pump. Installed a small clear line on the output return fuel line so when the engine did start he could see if there was fuel of a mix of fuel and air, bubbles in fuel, comng out of injector pump. Had the truck started within about 20 minutes of getting there. When he got the truck back to his workshop he then started to hunt for the cause and simply started at the fuel tank and worked forward. Problem was a significant air leak via the hardened O ring that is in the electrical connection for the fuel filter change indicator light.

 

This just came to mind; I resently was wrenching on the truck, after this no start problem began, and left the key in the on position for an extended period of time (longer than 30 minutes). Could I have burned out the GP controller. I checked all the GPs and they check out O.K.
Also I checked the water separator last night. Pulled up on the ring and nothing came out. Now tonight I found a VERY LARGE puddle of fuel under this area. Still nothing comes out when I pull this ring.

Still no vroom vroom

 

When I replaced my water seperator with an intigtated racor filter seperator, I disected the old water seperator, mine would not drain anymore either.

As it turned out, it was about 1/4 full of dirt and sand that had clogged the drain hole. After looking inside it, a simple solution would have been to gently stick a 3" nail up the drain and dislodge the crud.

Its just a theory, but maybe this is what happened to your water seperator. If enough crud collects, it could restrict fuel flow.

To prove this theory, you could simply temporarily bypass the water seperator to see if the fuel fows for you.

 

Did you figure out if the shutoff solenoid on the IP is working? It could have burned out with the key on that long

 

Yes, I applied 12v and removed it, I could hear it clicking.

Hey Dave S. or PLC7.3 you seem to be the go to guys. I need some help, would like something new to try tomorrow. Thanks for your help.

 

If the controler was working correctly. It would cycle on and off as the GP's cooled but it is a wonder it would turn over with that large a battery draw for that extended period of time.

The large puddle of fuel - when you pulled on the ring, it probably didn't seat properly when released. Especially if it hasn't done this before.

Being your not getting any fuel out when ring pulled I would go with the easy and change the fuel filter.

 

water sep on these old things is a given prob when i sits for awhle like over nite then it will allow air to enter the system this allows it to drain back to the tank most have been bypassed long ago but if not then take a 3/8 bolt and clam and just put it in the hose and clamp off this way you can still use it to drain the water off if need be and they will usally only work if the unit off or if you have a electric pump then you can pull the ring and some fuel will come out

luc to ya

 

Sounds like the water seperator has drained overnight.
So now you have a lot of air in the fuel system.

 

O.K. here's the results from Staurday. We pruged the system until we where blue in the face. And we are getting excellent flow at the IP. When we plug in the line to the IP we then get no fuel. We went as far as to remove all injector lines from the IP and crank the motor over. No fuel was present even then and I mean nothing, we dried all the fittings before we cranked, and there wasn't even seepage. We both think its a bad IP. I going to start looking for a replacement but I've seen them on Ebay for $250 and at Midwest Fuel Injection for $400. I just don't know, is there a huge quality differeence in IP's. Also if any of you think it still is air intrusion please let me know. My buddy is more familar with the Isuzu motor family.

 

Hey is an IP swap pretty easy. I know nothing about it, do I have to do any timing or need any special equipment.

 

Sounds like the fuel shut off solenoid is not getting power or has died.

With the key in the ON position, remove the front drivers side wire on the IP.
You should hear a faint click as you touch and remove the wire from the terminal.

If you use a test light, the wire should have power when the key is ON.

 

is it possible that the fuel shut off selonoid is my trouble...? starts when cold, runs while hot, and i turn it off for a couple minutes, will not start until cools down to some temperature again.
i did mention that the mechanic mentioned the IP, and had done some test involving lukewarm water over the injector lines. the truck started at this.
i have not replaced it yet due to the fact that these things cost a pretty quarter.
driving is become a plan in action.

so, i check this solenoid.
may be the truble.
m

 

Sounds like the mechanic did an IP test.
When it starts after some water is poured over the IP, time for a new IP.

 

starts when i have a fan blowing on the IP for a little bit too. takes longer than the water, quicker than the sit and wait.

 

No the FSS is recieving power, we also checked by removing the upper cover and applying power and checked the operation of the solenoid. Everything was operating just as it should. Also checked for 12v with key on. Everthing seems O.K. I can't imagine that I could be getting that much fuel to a the IP and still be battling a air bubble. I believe I have exhausted all tests and am looking at new IP's any reccommendations?