Hard starting IDI - Diesel Forum

SMOKNZ · 06-13-2006, 01:32 PM

My brother has a 94 E350. It has a VERY hard time starting. My thinking was an issue with glow plugs. We replaced them with no improvement. Checked for voltage at each one and had it. He replaced the lift pump as well and that didn't help. The thing has to crank for over 2 mins (no not continuous) to start. It starts just fine when it's warm. Can someone point me in the right direction!

Thanks

Bill

tim94f250 · 06-13-2006, 01:56 PM

Bill,
Sounds like you are having a problem with air intrusion. It is more than likely your return lines or the o-rings under the plastic caps on the injectors. Have a look for wetness on or around those caps and lines. You can buy a return line kit or injector install kit as they are also called. Check this out; www.dieselpage.com/dlk.htm They will cost you about $30. Once it starts, how does it run? Tim

pafixitman · 06-13-2006, 04:12 PM

Not really scientific but...

When cold, crack the fuel filter and see if it is low. If you take a bath in #2, then chances are good it is not an air leak. If it is low, then you do have an air leak. It will not be visable "spilled fuel", but the air is getting in and you are loosing the vacuum in the fuel system and having to fill the filter and purge air before she starts.

Did you use Beru glow plugs? Did you test the plugs, or the harness? One bad plug can cause you a lot of trouble - I know, I just tested and found my dead one last night.

Mr_Roboto · 06-13-2006, 04:47 PM

How long are the GP's on for initially? If there is a problem with the controller or plugs, the controller may not stay on long enough for the plugs to warm up. I've long since switched to manual control, I believe cycle time should be 6 - 8 seconds? Too short and the plugs don't heat up. Too long and they burn out.

As was said above, what brand of plugs were used? Some are known to burn out almost as soon as you install them.

SMOKNZ · 06-14-2006, 09:49 AM

Van runs fine after it starts. There is a schrader valve on the fuel filter, and if we press it before cranking and then crank it, fuel comes out right away. The brand of glow plugs?? I'm not sure, he got them from AutoZone. What brand should he have got, and where from?

Thanks

Bill

SMOKNZ · 06-14-2006, 09:54 AM

[ QUOTE ]
Bill,
Sounds like you are having a problem with air intrusion. It is more than likely your return lines or the o-rings under the plastic caps on the injectors. Have a look for wetness on or around those caps and lines. You can buy a return line kit or injector install kit as they are also called. Check this out; www.dieselpage.com/dlk.htm They will cost you about $30. Once it starts, how does it run? Tim

[/ QUOTE ]

What does this injector install kit replace? I didn't know there was a return on the IDI's, is there a regulator or something in the injection pump?

Bill

Mr_Roboto · 06-14-2006, 11:26 AM

[ QUOTE ]
Van runs fine after it starts. There is a schrader valve on the fuel filter, and if we press it before cranking and then crank it, fuel comes out right away. The brand of glow plugs?? I'm not sure, he got them from AutoZone. What brand should he have got, and where from?

Thanks

Bill

[/ QUOTE ]

Brand should be Motorcraft boxed, will say "Beru" on the plug. If you used Autolite, Champion, AC Delco etc DO NOT use them as they can cause serious damage.

Report on what brand plugs (were) and are in it, and how long your initial glow plug cycle time is, and we will go from there.

SMOKNZ · 06-14-2006, 12:07 PM

Bypassed the glowplug relay, from batt to batt connection, and did nothing to help it start... does this exclude the glow plugs? Plugs are AC Delco

Bill

tim94f250 · 06-14-2006, 12:54 PM

Check the voltage at the glow plug connectors. Should be the same as bat. voltage where you jumped it to. If that's ok, test all the glow plugs. As others told you, get Motorcrafts/Berus. The return lines are on the injectors, on top of each injector and beneath the hard lines. There are o-rings beneath the plastic caps, on the injector. So, in the kit you get eight plastic caps, sixteen o-rings, a bunch of clamps and cut to fit hose. Disconnect all the hard pipes, and take each side off intact. Lay it out and make a new side using the old as a template. Remove all the o-rings with a dental pick or similar tool. Take care not to scratch or nick the injector. Slime up the injectors with ky jelly and the o-rings. install the top o-ring first, then roll the bottom one over the top one. Get the side you assembled, slime the inside of the caps and install the side by pushing down until it snaps. Install the hard pipes and finish everything. It should start without having to bleed anything, but the glow plugs must be working. Tim

Mr_Roboto · 06-14-2006, 01:02 PM

Take those Delcos out ASAP. I've seen used ones, the tips were all twisted and swollen. IF ANY of the plugs do not come right out, then the tips may be swollen and you are in danger of one breaking off inside of the engine. If any bind in the least bit, do not try to force them and come back here for instructions on removing swollen GP's. Broken GP tips can very well ruin an engine.

Go back to the parts store and get "Motorcraft" glow plugs and start over.

mcr · 06-15-2006, 03:24 PM

Dont forget to check the fuel lines under the truck. I found a slight leak and it solved my problems. Check the easy stuff first.