Tried searching posts, but was coming up with nothing...

1989 E350 cube van with the 7.3IDI and 185K on the ticker

It's been a slow progression of getting harder to start each morning, typically takes a few cycles of the key and cranking for awhile, give it a bit of gas (accelerator), let off, keep cranking. cycle key, leave in the on position for about 30 seconds, start cranking again, then vrrmmm, huge billows of white/black smoke and chugs until it cleans itself out.

Today I installed a new glow plug relay, same very hard starting. I went back to the office, guys called wanting a ride home since van would'nt start. Told him to depress the gas a few times while cranking and over the phone i heard it fire up.

So, since it has a new GPR, that only leaves the glow plugs right? Super nervious about taking it in to get changed for fear of them breaking off and engine having to be pulled, heads ripped off, etc...

Anything I can check before walking the plank?

Josh

 

First, be careful to only crank on the starter for a maximum of 20 seconds and then wait at least 2 minutes before trying again. Otherwise, you risk overheating your starter.

It could be burned out glow plug(s). You can check them with a test light or ohm meter while they are still in. If you have any bad ones, it's probably a good idea to change them all. The consensus here seems to be that you should stick with Beru brand plugs with "Made in Germany" stamped on the side. Other brands have been known to cause problems.

When you turn the key to the on position and don't crank, do you hear the GP relay clicking? If so, when? What does the voltmeter on the dash do? You could have wiring issues.

 

have you replaced injector lines? if gray, they're factory and like mine, needed replacing. the one leaving the fuel filter (think it's a fuel bypass line) WILL develop an air leak and let fuel drain back into tank. mean to start, white smoke then black smoke. been there done that got the t-shirt.
speedrdr

 

check the injector lines to see if they're gray. if so, original and probably need replacing. they tend to develop air leaks letting fuel drain back to tank making starting hard with white smoke, black smoke, much aggravation. been there, done that, got the t-shirt.
speedrdr

 

sorry about the double post. arrgh! i hate dial up
speedrdr

 

Winter time if the truck is plugged in it started ALOT easier than it does now, but it's getting worse.

I did notice a small fuel leak that is steaming from the fuel/water seperator line...that needs addressed first and foremost, and I'll have to check the GP's and see what they are doing.

Might just take the truck out of service for a few days and have a shop give the thing a once over and hopefully get by for another year or two.

Return line kit, Buru GP's, where are you guys getting these from. Local stores act like I'm talking greek when asking for parts on this old thing, local international dealer is stupid expensive on everything ($40 for gallon of prestone anti freeze) if that helps put it into perspective..and that was cash and carry.

 

Autozone, the GPs are $10 each (Breu gremany)
www.mwfi.com ,Injector install kit "return line kit + copper washers" $35

 

I have a 93' Van w/7.3 idi. I had the same problem and tried the same things and nothing helped. I finally realized that the starter was not spining fast enough and replaced it making sure not to overtighten the trigger wire on the post on the solenoid which will make it break loose. Now the starter spins fast and the motor turns over within 2 seconds in the summer and 5 seconds in the winter even when it's 10 degrees.

 

The starter is a new one a few yrs back, and the motor zings over excellent. I think the combination of old old GP's and the fact I have a known leaking line off the injector pump which we fixed one time before is just compounding the fact of hard starts.

Made an appointment and taking it in Thurdsday night to drop off so they can tear into it Fri morning. Told him the urgency since it's our #1 tool shed on wheels and when that truck is down, we're basically stopping work since we use soo many thing ouot of it on any given day...he assured me it will be all done and working properly fri before they close.....Im crossing my fingers and toes. Right now it's a money no object thing, just make it right since this truck is such a vital piece in our arsenal...got the other truck getting a brand new engine installed this week elsewhere so once that's back we can limp through..but having 2 important trucks gone makes it tough. I'll pipe back in once I have it back and what they did, costs, if it works or not.

Thanks for the help fellas

 

I am having the same problem with my '90 F-250 7.3 IDI N/A. I plugged in the block heater and 3 hours later it busts right off. Will not start at all cold. I am looking forward to finding out what IHI found out. This is some great info. The GPR is slapping pretty good. I put a test light on the GP wire. The light flashed strong three times and then rappidly got dimmer with each click of the relay.

If I understand it right, put the alligator clip on the positive post and the probe on the tip of the GP. After removing the wire. If the light comes on, the GP is good.


Thanks,
pasotx.com

 

Sorry I did'nt update on this site, but here's what happened. Took "da bus" in thursday so the shop coudl get a head start since my luck is'nt the best, told them i needed it friday afternoon so we could get back to work on the job site saturday. I called Fri afternoon, they had the glow plugs swaped out, o rings in the injectors replaced, service done, just waiting on new return line...I drove out and he showed where one side was'nt seating real well, and honestly, it has been leaking for over a yr...just been neglected. New return line never came in friday, so they told me monday by noon.

Called monday, place they got the line sent the wrong one, said it'd be tuesday. I told them I needed the van back, and if there's anyway he could use emery cloth, or even install o rings into the return line ports for a seal, just do that and get it back together, we'll deal with it later. Picked it up, and WOW is all I can say..literally starts faster than my V10 in the F350...they found 4 GP's that were shot, installed new injector o rings, and sealed up the return line best they could...so far no leaks, but also no guaruntee since I gave them permission to do what they could as I needed it back...should've done this last year...for only $595 I'd pay to make this an annual maintenance item just cuz...and yes, the block heater still works, and that was how we were limping through into summer..leaving it plugged in. Sounds funny, but I'm actually looking forward to the cold and seeing how it does.

Josh

 

I found 4 of the eight glow plugs were dead. Replacement was a pain but uneventfull. Makes all the difference in the world. It now busts right off and sure cleared up the smoke at startup. Thanks for the tip on the anti-seize. Probably had two dead when I bought it two months ago. I replaced 4 and they were the Motorcraft/Behu. Curious, I called Autozone and they do not stock Motorcraft glow plugs. I found them at O'reilly for $8.99. There are some real idiots that work at auto parts stores. One guy told me all Motorcraft parts are made in Japan. He was amazed when I showed him "Germany" on the glow plugs. Another guy said all glow plugs are the same.

BTW - I think the Soleniod died during troubleshooting. Fun fun.

Scott
90 Ford F-250
7.3 NA