The truck would start fine (one crank) 2 weeks ago when the fuel return line on the back of the engine split open. I replaced the the supply and return lines (finished yesterday) from the tank to the engine with Trident Marine fuel lines, the in tank module is new also. If the truck sits for a couple hours its hard to start. Seems like Im getting air in the lines and have to crank a couple times and give it a little throttle to get it to start. It will sputter and let out a big cloud of white smoke but then runs and drives fine. Is there someplace that the air may be trapped that I didnt get bleed out thats causing this or is the air coming from someplace else?

 

Sounds like you're losing prime. Maybe the old in tank module or fuel lines had a check valve that wasn't replaced? Once the truck is running it should take care of purging any remaining air on it's own.

 

The tank module has been in the truck for about 2 months and I never had the hard starting problems after the install only after the fuel lines. I dont think there is any kind of check valve on the old lines.

 

I checked the truck when I got home from work tonight. I could smell diesel fuel but the only place I could find any trace of fuel was the bottom of the fuel filter. Is it possible that its leaking at the WIF sensor? I have a spare fuel filter laying in the truck and am going to change it out in the morning if the weather is descent (no garage).

 

did you ever get this figured out?

 

I also wonder if you figured this out. I just changed my return line nothing else, and mine starts harder now.

 

I changed out the fuel filter, changed the pre-filter and tightened all the hose clamps on the fuel lines and all is well now. Im not sure which actually fixed the problem because I did it all at the same time. The truck never takes more than one quick crank to start now.