Engine/Transmission (1994 - 1998) You guys need to read this!!! RE: Hard Starting + low mileage

[Flying_gage]

Hey all,



Never heard of this before and want to pass it along to all of you.



So here was the symptomology of what has been happening with my truck:



- Hard starting requiring " a little pedal"

- White smoke on start up

- Low mileage

- Low power



Here is what I checked, (that was okay):



- TPS Volatge

- Overflow assembly

- Fuel filter



So, I wrongly assumed that since the truck sat for 3 months on a dealership lot, I had "algae" in my tank. I felt this was supported by my needing to change fuel filters every 2-3000 miles, (that sucked!).



I dropped the tank today and even before I had it down, I noticed that one of the supply lines was "wet" with diesel fuel. Looking closer, I noticed that there was a crack in the line where it entered the tank. I still thought maybe that I had algae in the tank but lo and behold when I opened it it was clean as a hospital O. R.



So I really thought about it and now everything has clicked. The line was cracked just enough that it allowed air in at all times. So I will update as soon as I get the new assembly in and let you all know if the above things are fixed.



Here are some pics. of the assembly. You can see how rusted both the return line and the supply line were.



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[xpetecx]

Man this topic seems to be going around lik the plague. I had the same problem on my 96, and so did a few other members.

 

[MHalloran]

Flying gage, that looks just like my module that I swapped out this weekend on mine. Just a heads up for ya, module was dealer only item & they soaked me for $340. They gotcha by your privates, if ya know what I mean. Check your fuel lines as well dude. Larry B's new hoses, sells by the foot.

Xpete, you already know where I stand with my hard start status.

Talk later guys. Mike

 

[Signal73]

the steel elbows on the top of my 95's tank were rusted and leaking and when I did my fuel lines, I spotted it.

 

[MHalloran]

the steel elbows on the top of my 95's tank were rusted and leaking and when I did my fuel lines, I spotted it.

Signal, Did ya install a new module? Would anyone know if a leak at this point would also create a hard start? Mike

 

[Signal73]

I actually cleaned it up real good, sanded it to bare metal and, Ahem, JB welded the elbow to fix the problem Been good for at least 10 months. Yes that area, along with any other air leak, can cause the fuel system to loose vaccum and give you trouble starting.

 

[LMcCary]

I had a similar problem on an '03. The line was cracked just as it started accross the top.

 

[Flying_gage]

Update

Well I went with the vulcan draw straw as I couldn't justify the $350 the dealer wanted. Everything else was fine so, it kind of made sense.



And wow! Big difference! The truck now starts right up without any pedal assist; and in fact, I will now need to turn down the idle as it is idling a 100 rpm higher now. It cruises alot more comfortably with the rpms down anywhere to 50 - 100 rpm's through it's range.



When I looked closer, there was alot more rust through than I originally thought. Holding it up to the light I could see numerous pin holes in the top of the housing.



I can't speak highly enough about the vulcan. For $40 bucks it is cheap piece of mind. And by the way, my fuel lines look pristine. The top of the module is poorly designed and water and muck accumulates there.

 

[Matt42]

Where do you get a Vulcan Draw Straw? Could someone who is handy make something up out of steel tubing?

 

[SFrey]

look here https://www.turbodieselregister.com...9153-started-new-fuel-system.html#post1622510 I made Fittings to go into the rubber groumets on the fuel module, can make the center hole any size or thread.



scot