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AAARGH!!! I Need help!

Chefboy

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Location
Kansas City
Maybe someone can help me figure out why my 6.5 won't start...
Yesterday, I installed a new aftermarket fuel filter assembly (fuel manager), along with new fuel lines and injection return lines (the old stock stuff was looking pretty shabby, so I thought it would be good to replace it now rather than during our trip to Yellowstone this summer). Once I installed everything, I cranked the engine several times with the f/sol fuse removed, returned the fuse to its rightful location, and it started right up. I ran it at idle for about 10 minutes, then drove it around the neighborhood a bit, shut it off, and restarted it numerous times... all was well and I slept like a baby.

This morning, I tried to start it, but it would just crank and crank and crank, but never fire up. I checked all of my negative grounds, which are good. I checked the fuses and wiring harness connections, and they seemed to be fine as well. After all that wire jiggling, and multiple attempts at starting it, it finally fired up, reluctantly though. I gave thanks, ran it a while, drove it a while, shut it off and restarted it a few times, and then drove it to work... which is where it'll be staying tonight, 'cuz it's not starting once again.:mad2:

I'm not sure what to do, so any suggestions?

The PMD is a year and a half old, and it's been relocated on a deep heat-sink, so I don't think that that's the problem... but maybe.

I'm running on straight diesel fuel, and the fuel is fresh.

I want to check for air in the system, but the new fuel manager does not have the same kind of air-bleed setup, so I don't know how to do that.

I also thought that the fuel shutoff solenoid could be bad, but I replaced it just about 18 months ago (when I was chasing rabbits after buying the vehicle). Oh, and it did trip DTC 13, so again, this could be my problem.

Any suggestions?
 
What AK & Leo said, It ran fine before right? Throw a pmd on it to see. Yours is mounted on intake?? GP's good?
 
Yes but is it on intake? GP's can go bad in 12 months, what brand are they?
The GP's are the SS Diesel Supply "Instant-Heat" Glow Plugs with new Terminal Connectors. When I put them in, I also added a new Glow Plug Controller/Relay and Glow Plug Override Kit with a push button. The PMD is Mounted up and to the right of the intake.
 
How do I do that?

Simple, unplug the wire connector & the FOS can be removed from the IP. Then remove the snap ring & the plunger will fall out of the cylinder. Reinstall the cylinder back on the IP (don't loose the little rubber O ring that seals the cylinder to the IP). Plug the connector back in yr done. I removed mine for trouble shooting last winter, no intentions of ever replacing it. It's not needed.
 
Simple, unplug the wire connector & the FOS can be removed from the IP. Then remove the snap ring & the plunger will fall out of the cylinder. Reinstall the cylinder back on the IP (don't loose the little rubber O ring that seals the cylinder to the IP). Plug the connector back in yr done. I removed mine for trouble shooting last winter, no intentions of ever replacing it. It's not needed.

OK, thanks! I've pulled it, and took a picture of it. So, am I removing the black plastic tip, shown in the bottom of the picture? Does it just pop off, or do I need to manhandle it?

IMG_1884.jpg
 
Whoa... Is your fsol working? If you turn the key and it clicks, there is mo reason to disable it.

Go through the checklist... Carefully! Check all the obvious stuff... It ran fine before you did the new filter- start there, and with the lift pump
 
The GP's are the SS Diesel Supply "Instant-Heat" Glow Plugs with new Terminal Connectors. When I put them in, I also added a new Glow Plug Controller/Relay and Glow Plug Override Kit with a push button. The PMD is Mounted up and to the right of the intake.

this could be your problem you better check out the glows. I had them and they failed in 3-4 months
 
No No NO look close under there you will see a snap ring that is holding the entire plunger with spring assembly in. Remove the snap ring & all the inside of that will all come out...

Snap Ring... got it. I should've read it more closely.

So it now looks like this...
IMG_1885.jpg
This is my old F/Sol, so I'll just swap it out with the newer one. If that doesn't fix it, I can always put the newer one back in.
 
Replaced fuel manager,ran good before!.
by the looks of it the filter wasn't bled right and has a lot of air in it

do the clear IP return tube test
 
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