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Engine/Transmission (1994 - 1998) starting problems

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2nd Gen Non-Engine/Transmission modified fuel pick

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I'm back to TDR after a two year break. I had to quit with truck mods so I haven't visited the site very much.



I'm having starting problems after the truck sits overnight or for an extended period. I've replaced all rubber fuel lines @ 160K miles. New fuel filter 1,000 miles ago, original injection pump and lift pump. I know the batteries are almost shot, but I don't think it should cause the problems I'm having.



It starts fine and when I take off and idle up the driveway, in starts to sputter, and you have to goose it to keep it from dying. If it dies, you crank it over again giving it a couple pumps and it fires up sputters and runs normal.



Any ideas?



I have never adjusted the timing.
 
:) Check for air leak on your fuel heater. . it can suck air around the electrical plugin, make sure it hasnt burnt up. if so just remove heater element entirely, youll never miss it!! :D
 
Most of the time you can't tell if the fuel heater is leaking air by looking at it. If removing it solves your problem then just leave it out. You don't need it. If it does not solve your problem. When you replaced the fuel hoses did you use diesel rated hose? If you used normal gasoline rated hose it will fail even sooner than the original hose did. The stuff at the parts stores is usually not diesel hose in spite of the clerk's opinion. You might want to read this:

http://dieselram.com/ubb/ultimatebb.php?ubb=get_topic;f=45;t=000007
 
put new hose on the return line... got a bad hose clamp... but its tight enough to not leak air... .



It is better but still sputters... ... I guess I'll look inot the fuel heater element..... might be a dumb question..... but here goes... .



If you take the element out what do you put in place of the fitting for the element?
 
Have you read the link I posted above? There are pictures. The screw that fastens the fuel heater into the fuel heater/pre-filter is just an adapter (picture in link above) so the fuel heater can be removed and the pre-filter will fit up in its place (picture in link above).
 
Just finished up..... I took the fuel heater out... I have the new style heater. It was not burnt at all and seem in great shape... the only thing I seen was that the two square cut o-rings were dry rotted and had small cracks in them.



I took the heater out and sealed the fuel bowl to the block as suggested. I'll see what happens tomorrow morning when I try to start it.



I also tested fule pressure at the filter with the test gauge. I have 20-21 pounds at idle and 25-26 lbs @ 2000 RPM... .



I believe this tells me the lift pump should be alright?
 
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