I installed a new FSS yesterday on my all stock '96. I still have the hard staring issue, (I replaced the return line check valve in the Summer), although I set the length of the rod the same as the old one. If I still have an issue, do I need to extent the rod, or shorten it? Any suggestions are greatly appreciated.

 

I’d be inclined to believe you have a leak on the suction side between the pump and tank. You might have someone pressurize the tank with 5-8 psi of air while you look for any leaks in that path

 

I don't smell any fuel, but I'll take a look. It starts fine once warm, but letting it sit over night and it's a bear. I also now wonder if it could be the fuel pump.

 

You likely wont smell fuel if you have a leak on the suction/supply side - there is no pressure there to force fuel out. +1 on Honobia's suggestion.

Unless you are way, way off on the FSS rod length, that shouldn't prevent the truck from starting. You should get the rod length adjusted as close to perfect as possible, but I don't think that's where your starting problem lies.

By "hard starting", do you mean it takes a lot of cranking before the truck starts? Does the starter spin the engine over easily enough? If you push the primer button on the lift pump - how many strokes does it take before you hear the overflow valve (OFV -what you called a check valve) squeal as it allows fuel past it into the return line?

 

The truck will start, but it take a fair amount of cranking. I adjusted the FSS rod to the same length as the old one, so I don't think that's an issue anymore. The starter spins it just fine. I haven't fooled with the primer button.

 

One of the main sources for a leak and hard starting on the "P" pump motors ir where the electrics plug into the the fiel heater above the filter, pull the plug if it's wet that's your problem. Either replace or eliminate it and should have no more problems with starting.

 

Thank you. I'll check it tomorrow.

 

Any updates?

 

Not really. I checked the plug as suggested by nonrev, and that was okay, but that's as far as I've gotten. It starts fine, (even if it's been a few days since I drove it), as long as the nose is down hill. I hope to get back to it after Christmas.

 

This would be my guess. It's a very common problem. Like nonrev said you can just eliminate it with no ill effects. And it doesn't necessarily have to be wet to be the problem. Any updates on the issue?

 

I pulled the connector, and it wasn't wet. I ran out of patience took it to a diesel shop near me, (Diesel Concepts in Prince George, VA). After four or five days they called and told me the water drain on the fuel filter was leaking down. I didn't think it could be that simple, as I never smelled any fuel even after it sat for several days. They swapped that out and it starts like new. Unreal. They took their time with it. I knew they could only duplicate the issue once a day. Nice folks, but I feel like a dope for not finding something that simple.

 

pipefitter, thanks for posting the fix on this as so many folks don't, and I now have one more tool in my toolbox for trouble shooting hard start problems

 

I'm still baffled that it could be that simple. They have a couple of mechanics there with knowledge of the old stuff.