Same fuel problem as always - Diesel Forum - TheDieselStop.com
7.3L IDI Diesels (Not Power Strokes) Technical discussion of topics related to vehicles powered by the 7.3 Liter In-Direct Injection Navistar engines.

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post #1 of 34 (permalink) Old 08-17-2014, 05:23 PM Thread Starter
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Same fuel problem as always

Have owned 3 of these in the last 15 years. Currently fighting the common start in morning run for 5 seconds & die problem. Installed new return line kit, didnt fix problem, lift pump yesterday, didnt fix problem. My question now, in what manner does half the fuel leave the filter? does it bleed back thru pump? or back thru return line?

This is my work truck, so I have to run it everyday, if everything works out I should be able to burn up a starter by the end of the week.

1991 F350 custom DRW, 4x4, 11' service box, 7.3

1982 Mercedes 240d
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post #2 of 34 (permalink) Old 08-17-2014, 05:44 PM
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Have you checked the line from the filter to the IP? It can drip onto the valley pan and you won't see it. I suppose if you have the cap off the Schrader valve, it might allow air to suck in while the line leaks out.

1994 F-350 7.3 IDI Turbo, crew cab, E4OD,4:10 L/S, LB, Dually
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post #3 of 34 (permalink) Old 08-17-2014, 06:08 PM
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You've got two rubber compression fittings on each end of the line Chuckster's referring to. If they need tightening or replacing that can be your problem. But you don't want to tighten them real tight like a flare nut fitting. IIRC you've got them on the steel line from the transfer pump to the filter too.

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post #4 of 34 (permalink) Old 08-18-2014, 08:54 PM Thread Starter
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I'm sure it's something stupid, amazes me how you can buy something that's patched together with different color caps, hoses, clamps & it works fine for about 2 weeks then goes completely to crap. Now the fun part of dumping money & time chasing problems..

1991 F350 custom DRW, 4x4, 11' service box, 7.3

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post #5 of 34 (permalink) Old 08-20-2014, 02:15 PM
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If you take a straw and put it in a glass of water then hold your finger on the top, withdraw the straw, the water will stay in the straw, let air in and the staw will empty, same thing as a fuel system, if air gets in, fuel will return to tank. the Olives that seal the steel lines from filter to IP pump get hard and no longer seal, all you have to do is bump that line and the old ones will leak air in. Dieselorings no longer carry them, but an IH dealer might.

99.5 F350 XLT Lariat 4X4 4R100 4.10 DW CC LB Centurion conversion, 183K miles Garret Turbo, Radio SD &Tape, SP Performance 40-60-80 chip, 100 Gal.Transfer Flow W/Trimax Control Aux. fuel tank. ScanGaugeII, Boost, EGT, Trans. Temp. Oil Temp. Build date 03/99

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post #6 of 34 (permalink) Old 08-20-2014, 03:01 PM
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Any decent parts house or injection shop, they're commonly used in all sorts of applications.

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'91 F-250 SC 4X4, 5spd. ATS Turbo, 3:55 diff.
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post #7 of 34 (permalink) Old 08-20-2014, 04:11 PM
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I will confess my sin:: I used 2 Viton O rings stacked at each end. Been perfect for 3 years now! Statute of limitations is over, right?

1994 F-350 7.3 IDI Turbo, crew cab, E4OD,4:10 L/S, LB, Dually
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post #8 of 34 (permalink) Old 08-20-2014, 08:08 PM Thread Starter
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Probably what it is, last night I pinched supply line off behind lift pump & it started this morning. Filled up with fuel today so it will behave till it gets down to 1/2 tank. I can see why people go to an electric pump setup. $25 I could add 12 volt on/off valve on supply line behind lift pump.

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post #9 of 34 (permalink) Old 08-22-2014, 10:31 AM
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Originally Posted by quackattak View Post
Probably what it is, last night I pinched supply line off behind lift pump & it started this morning. Filled up with fuel today so it will behave till it gets down to 1/2 tank. I can see why people go to an electric pump setup. $25 I could add 12 volt on/off valve on supply line behind lift pump.

or just fix the problem correctly and have it last another 20 some odd years?

New truck: 1988 F-350 1 ton dualy 2*4, 7.3L IDI Naturally Aspirated, Dual tanks with Camper package.
Mods: Enhanced gauge cluster; Transmission temp, rear diff temp, coolant system pressure, Vacuum pressure, Fuel pressure, Crappy tire Air horn Kit, Raycor pre filter/water sep. All LED Dash lighting, Parker LFS tranny filter, super duty tranny cooler, gerret turbo, waste gated (pending).
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post #10 of 34 (permalink) Old 08-22-2014, 04:56 PM Thread Starter
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Have replaced all the common things including the 70's technology olive seals, this is a good engine with a lousy fuel system. Air intrusion has always been a problem on these, then on top of that the only way to bleed system is with starter. Was looking for more ideas on other ways to repair system. I drive this 25-30k mile a year, fascination about a 20 year repair makes no sense, I'm sure I will have moved on to something else & there will be far fewer of these around.
After all I have read & tried myself, I will be going to the holley red top electric pump setup.

1991 F350 custom DRW, 4x4, 11' service box, 7.3

1982 Mercedes 240d
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post #11 of 34 (permalink) Old 08-23-2014, 10:51 AM
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good luck with that, I just did mine properly, now it starts perfect every time and cost less then the electric pump., but as they say your cash!

New truck: 1988 F-350 1 ton dualy 2*4, 7.3L IDI Naturally Aspirated, Dual tanks with Camper package.
Mods: Enhanced gauge cluster; Transmission temp, rear diff temp, coolant system pressure, Vacuum pressure, Fuel pressure, Crappy tire Air horn Kit, Raycor pre filter/water sep. All LED Dash lighting, Parker LFS tranny filter, super duty tranny cooler, gerret turbo, waste gated (pending).
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post #12 of 34 (permalink) Old 08-27-2014, 01:43 PM
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I have similar problems. I've changed all of my return lines and olives. Installed clear lines in key points. I'm still getting air in the coming off the front of the IIP. I have switch installed for instead of the come temp switch. Here's what happens when i switched it off. Any ideas?
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post #13 of 34 (permalink) Old 08-27-2014, 02:22 PM
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Here's the video i took.
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post #14 of 34 (permalink) Old 08-27-2014, 02:27 PM
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Here's the video i took. Hopefully.
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post #15 of 34 (permalink) Old 11-20-2014, 02:37 AM Thread Starter
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Follow-up.
Truck went to starting half decent again, so my electric pump just rode around with me. As soon as the cold weather hit 3 weeks ago, the thing went completely to hell. Have been putting battery charger & plugging in at night, the final straw was Sunday, went out to start truck at 9am & finally got it going at 11:30am.
Stayed up late & converted to electric pump, bypassed the mechanical pump. This has made the truck as reliable as my old Mercedes. This week has been awesome, no more battery charger, just plug in at night, in the morning while the glow plugs heat up the electric pump primes everything & starts instantly, no hesitation, just idles perfect. Runs down the road great, best thing I have done to one of these.

1991 F350 custom DRW, 4x4, 11' service box, 7.3

1982 Mercedes 240d
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