Happy New Year!!! Nothing like starting the new year with engine problems. I was hoping you guys might have some insight on this. I have a 92 F250 with the 7.3L non-turbo version. I live up in Washington, and it's pretty cold out lately. Last couple of weeks, I'll start it up, it runs for about 2 seconds then dies. Then I have to crank it for about 20-30 seconds or so, then it'll fire, run rough for awhile, then be fine for the rest of the day. Now, in looking through the posts, it totally sounds like an air leak in the system somewhere. I tightened down the filter on the fuel/water separator, and tightened down the lines leading into it. It has new return fuel lines and o-rings, just a few months old, new set of glowplugs, and also a new injector pump. (also a few months old....expensive summer) I don't really see any fuel leaking anywhere. Also, and I suspect this is important, I had it parked in my buddies heated shop for a couple of nights, and it didn't do it at all in the morning. Just when it's cold out. I keep it plugged in, but that does nothing for the fuel lines. So what do you think? Can I get away with just a new filter, or is there a way to diagnose where the air leak might be? Or could it be something else? Thanks everyone, in advance.

 

I have heard of people using a clear plastic test line to look for bubbles or air in the fuel. I also wonder if you could put some vise grips in strategic places to pinch the rubber lines, and see if you can narrow down where the leak is.

 

If you have no visible fuel leaks, check for loose connections on the suction side of the lift pump. Plastic lines at the selector valve, pin holes in the steel lines would be places to check. I am thinking plastic or rubber hose as these get less flexible due to the cold.

 

A new fuel filter will do nothing, I have same problem going on. Starts fine when 50 + in the morning. Tried seafoam this morn after I started it on starting fluid. 26 deg. tomorrow morn, we'll see what happens.

 

The rubber seals in the supply line to the pump are also a cause of this. Mine were bad and they looked fine when I put the line on after the engine swap. I got two new seals from Ford for 4 bucks now she starts after the engine turns over two times.

 

Running 2 seconds and dying tells me the leak is very close to the IP.

The supply line from the filter to the IP or even a leak in the IP seals.

Check under the IP for wet spots.

 

After 2 cans on Seafoam, She started on her own. I you had a fuel leak it would die every morn. reguardless of temp.

 

Temp can affect air leaks in the fuel system.
Steel, plastic and rubber or vitron parts, all expand and contract at different rates.

 

My guess is that one of the caps on the return lines was bumped when you did the glow plugs. Once the o-rings get old and hard, you can't move them or you'll have a never ending cascade of leaks untill you change them all. A return line kit isn't that expensive (about $35 or so). You won't always see fuel leaking out where air leaks in.

Also, parking facing uphill seemed to cause similar starting problems until I found my air leak (fixed with a return line kit from Autozone). Also, it seemed to leak down more when the front tank was selected.