Archived 2'nd generation can't get fuel lines primed

[Coalsmoke]

I drained some fuel / water using the drain on the bottom of the fuel filter and now I cannot get fuel travelling to my injectors. I can have a couple of high pressure lines disconnected at the top of the injectors and with the clamping nuts completely loose and no fuel is coming out the sides. I have tried loosening almost every banjo fitting I can find and cranking the engine. As far as I can tell I have the filter primed and fuel is getting to the pump. When I loosen the nut off on top of the filter and crank the engine, fuel oozes out. When I clamp that nut down and open the 19mm banjo fitting that is on the side of the pump (from the line that connects the filter to the high pressure pump) and then push the rubber priming button, fuel gushes out of the banjo fitting. When I close everything and crack open the little bolts on the sides of the injectors (whatever they are for, maybe return lines?), and then crank the engine, after about 10seconds of cranking a few little air bubbles can be seen coming from the fitting.



Any help is very much appreciated. I am totally out of ideas and the truck never came with a manual.



Thanks very much guys,

Stephan

 

[jkeyes]

I just got done rebuilding a '99 2nd gen and I had to crank the hell out of it to get it to finally fire. But it finally did

 

[Gary - K7GLD]

Just be careful to only crank in short bursts, with plenty of starter cool-down time!

 

[Coalsmoke]

I've been cranking 20 seconds at a time. Should I have everything closed and tight when cranking or should I have some sort of bleader open? Also, when I push in the little rubber primer, there is so much resistance I am almost breaking my finger. Is this normal?

 

[Extreme1]

High primer button resistance doesn't sound right but what is hard to one person might not be for another. If you have fuel to the pump inlet, and it pushed fuel out when the engine is cranked, it's getting fuel that far. It should gush similar to when you are priming it.



To make life really easy on the starter, take the nuts on a few more cylinders loose. When you crank it, hold the pedal to the floor, it will allow more fuel through the injector pump.



You are looking for fuel flow throught the lines to the injectors. When you get fuel to the injectors, tighten the nuts back down and it should start up.



BE VERY CAREFUL! The fuel is under high pressure. High enough to cause poisoning or death if you get it shot through your skin. Also, if it hits a trouble light and causes the bulb to break you could ave a fire.

 

[Coalsmoke]

ok thanks, I'll go push the primer another 50 times, loosen all 6 nuts and crank away.

 

[Cliffman]

Coalsmoke, this might be obvious but are you sure your lift pump is working.

 

[Coalsmoke]

no, but it was fine before I canged the starter. How can I check it. I've been cranking so much I can hear my two (rather new) batteries starting to get weak.

 

[Extreme1]

It takes 120-200 pumps on my primer to get the filter filled up. Be sure the fuel has an outlet when you're priming it. either the bolt in the top of the filter housing or the inlet to the injector pump.



Try using a broom handle, I've seen posts from others who have had a much easier time that way.

 

[PUMPERDUDE]

Sounds like your lift pump is shot or weak. You were ok untill a little air got in the system. If the lift pump is working right,after about a hundred strokes or so you should hear fuel squishing through the overflow valve and youre good to go. Wouldn't be surprized thats it with 205k on the ticker. To check it ,you need to put a gauge on the inlet banjo fitting to the injector pump. Good luck.

 

[Coalsmoke]

would it possibly be the on/off fuel solenoid? Id there any way to check the lift pump without a gauge. If not, what should it read when cranking?

 

[PUMPERDUDE]

That could be possible. Make sure the solenoid is picking up all the way when you turn the key..... The fuel pressure should be 18-20 at idle ,25-30 running.

 

[Coalsmoke]

I just got back in. it is the solenoid. I'll be making it a cable deal tonight. Oh, gotta love these automotive nights that never end. I replaced the starter last weekend. It sticked twice, once for . 5 sec and once for 2sec with burnt insulation smell afterwards. I guess the replacement starter killed my solenoid. I got another starter this morning, and it appears that they changed their design, probably b/c of this reason. Too bad I had to get one of the last lousy ones



Thank you so very much all for helping me tonight. I'll let you all know how it works out.



PS: If anyone has a link to the cable solenoid conversion, please feel free to post it.



thanks again, you guys are the best.

 

[britannic]

Here you go: Manual Shutoff Control

Originally posted by Coalsmoke

I just got back in. it is the solenoid. I'll be making it a cable deal tonight. Oh, gotta love these automotive nights that never end. I replaced the starter last weekend. It sticked twice, once for . 5 sec and once for 2sec with burnt insulation smell afterwards. I guess the replacement starter killed my solenoid. I got another starter this morning, and it appears that they changed their design, probably b/c of this reason. Too bad I had to get one of the last lousy ones



Thank you so very much all for helping me tonight. I'll let you all know how it works out.



PS: If anyone has a link to the cable solenoid conversion, please feel free to post it.



thanks again, you guys are the best.

 

[Coalsmoke]

Thanks guys. It's 2 am here and I just finished the manual control. It's a little funny having the key and fuel shut-off independant, but I'll get used to it. So, I'm up and running (although a little tired) and ready for the morning.



Thanks again guys