I bought a used '94 2500 a couple of years ago. I then loaned it to a friend to use for a while . When I needed it for a weekend, he scrambled to clear the fuel filter because of "water in fuel" light was on. Prevoius owner said "WIF" light comes on when it rains. In the process, the bleeber bolt for the filter housing was stripped. No bolts at Dodge. We "rig" it best we can. The friend continues to use truck. Later, the hardline from filter to injection pump cracks. A new line goes on. Friend fries a starter when trying to get it running. A couple of weeks pass and truck wont run. A call to previous owner and I find out about the fuel shutoff switch relay. I replace the relay and solenoid works.

I have had 3 people (none are what I would call pros) try to bleed the system. No luck. Its a pain to use the primer bulb so we used a compressor to get fuel to filter. Crack the banjo bolt at the injector pump and have fuel. I hope its not the pump thats wasted.


Search is getting me more confused.

Can someone point me to a procedure that will step-by-step eliminate any missed things to check ?

Thanks in advance.

 

You could get a fuel pressure tester and a fitting to check the pressure downstream from the lift pump. Should be 25psi or greater at idle. They dont usually die though.
You might have cracked hoses leading from the hard lines at the bottom of the cab that lead up to the heater and the return from the pump thats routed behind the fuel filter. Even if they dont show fuel they might be sucking air.
Other possibilities are a cracked pickup line inside the tank. You could completely fill the tank to rule that out.

 

Cant get it run at all.

How about a detailed prime how-to? Anyone know where to find this info?

 

If you get fuel to the IP, but it still won't start, I would try to crack open the nut on the injector lines. It sits right top of the injectors where the fuel line runs into them. A 17 or 19 mm open end wrench will do the trick. Open a few of them no more than one turn, max, crank it and see if fuel comes out from there. If fuel does get there, it may start, no big deal, just tighten them back up. If the engine starts, but still runs rough, it may purge itself and smooth out. If it does not, repeat the process with the rest of the injectors. I have had to do this to mine. Good luck.

 

We tried to crack the injector lines and got no fuel. If I could get a dribble of fuel, I would quit yanking my hair out by the handfull.

This is why I'm looking for a "tricks of the trade", "start here and do this first/next...look for this ect..." guide.

This is nothing like the 3 cyl. Ford tractor I used as a kid.

 

If you get fuel to the IP using compressed air, but no fuel to the injectors using the starter, bummer. My next guess is disconnect the banjo and crank the engine, does fuel come out? If not, check the lift pump. Air may be pushing fuel to the banjo, but the lift pump may not be working correctly. BTW, you are learning the tricks of the trade, welcome to the school of bald people.

 

Another forum has suggested I look for a loose/crusty connection at the shut-off solenoid. I remember the solenoid was moving when cranked but might not be getting full 12 volts.