Random Stalling

[ctdiesel]

I’ve tried looking through various threads to see if this has been covered, but so far I only find posts that are in some ways similar but not exact. So I am looking for a bit of help.
I am having random starting issues. At first I thought it was a glow issue because the truck would start with temps above 40, but not below. So I tested the GP controller and it performs as it should. Then I thought it was the GP’s, so I replaced them with Bosh Duraterm’s (2 of the old ones were bad with a third being questionable). Truck started and ran fine, so I decided to drive it to work.
Later that night I went out to see if it would start with the temp around 30. It did but only after cranking for a bit. With that in mind I decided to pull the truck into one of the bays at the firehouse for the night. Temp there is a constant 68. In the morning I got in to leave and the truck would not start. I bleed the valve on the fuel filter, no air and good flow. I bleed the drain at the t-valve, no air and good flow. Cranked the truck for a good while and it finally came to life.
Any ideas on what can be causing this starting issue? It almost seems like a fuel issue, but I do not get any air indicating a leak.
So far I have: Cleaned the filter sock, new lift pump, new GP’s, new fuel filter.
BTW, Truck cranks strong. Both batteries are fairly new as well as the starter. Grounds have all been cleaned and tightened.
Thanks for any help.
Eric.

 

[Burning oil]

Got a PMD to try?

Edit: I assume you have a ds4 ip? What year truck you working on?

 

[ctdiesel]

PMD is new from Heathto replace a faulty one from Heath (old one was about 4 y/o). But, not trusting that one, I have switched the new on out with another known working one from a friend. So I am almost positive that the PMD is not the issue. Also tried several different hook up options such as the older harness and direct to OEM connection. Truck is a 2000. 3500. To me it almost seems like the truck looses its prime after sitting. But the only reason I am ruling this out is, one day it will start the next it won't. Thats is why I was leaning towards a glow issue, but again I have tested and replaced some of the components. If the truck always did the same thing it would be a bit easier to diagnose. Looks forward to hearing any more possibilities. Thanks.
Eric.

 

[ak diesel driver]

put a clear hose on the return coming out of the IP and then have someone else crank it while you observe the clear tubing

 

[HighSierra86]

Have you tested the fuel pressure with a guage at the t-valve?

With the no-start conditions are you getting any other lights on the dash? like the security system?

 

[JMJNet]

What year?

If you are loosing prime, chances are the fuel filter manager may be leaking at the bottom where the fuel heater is? It is buried behind and below the manifold.

 

[WarWagon]

Park nose up and air leaks are worse. Nose down and the truck is easier to start with an air leak. Fuel is less likely to drain back when nose down.

If you do not see air bubbles from the above clear return line, let it sit and have a friend crank the truck to check for air.

When it starts does it blow a bunch of smoke?

The fuel system priming itself cools the glow plugs off. Best to start cranking before the GP light goes off to prime the system.

Head and rotor wear in the IP can show up as hard starting as well as air leaks from the injectors. Check for air first.

Miles and miles on injectors?

 

[buddy]

The diagnostic checklist has a bunch of questions to help the diagnosis.

 

[Acesneights1]

where are you in CT ?