Started one week ago today. If it sets at least 10 minutes you have to spend at least a minute running the starter with the acc. pedal on the floor to bleed out the air. You can bleed the air out of the filter and there is air and it will start right up. Running the lift pump at least three minutes helps a little. The rubber lines are new, there is a check valve between the filter and lift pump on the filter, the lift pump is new ( OEM ), the IP and PMD were replaced under warranty less than a year ago and was working great till last Sunday. All clamps have been tightened. No fuel under of on the motor. Any ideas or comments would help!!!!!!!!!

So the valley is free of diesel fuel? I'd suspect the fuel heater is leaking as mine is, but I have a few drips of fuel on the tranny bellhousing and some at the back of the valley.

You need to drop the tank and pull the fuel sender unit out, thats probably the source of the air leak.

Dry as a bone in the valley and on the trans bellhousing.

A leak in the valley wouldn't be the cause of your air problems anyway, it would just be a leak, air has to come from between the lift pump and the tank.

I have to bleed the air from mine, could that be I have both problems.

Do you get air out of the bleed all the time? If so, then yes. One more thing to add to your list of projects ;)

I never thought of it before, but TDG is right. Between the tank and the lift pump is the only place in the system where there's negative pressure, where a leak would suck air. Everywhere else is pressurized (if the lift pump is working) and a leak would drip fuel.

A lift pump thats only works part of the time might cause a vaccum to be created anywhere before the IP. Maybe a bad OPS is showing up here. You might "TRY" jumping around your OPs at your lift pump relay, for a test, to see if that changes anything. If it does then you can decide how to fix it for good.

Fooled with this problem all morning and looks like the CAT filter was less than half full of fuel but it will still run and good after you get it started. Even after bleeding it several times it will still run but it did not fill the filter all the way to the top. Someone explain this!!!!!! Filled the filter FULL by hand then bled it again and it works perfect. Why it has run for months then gave trouble blows me away.

You can purchase the whole tank sender unit, aftermarket units run about $70 and up, ACDELCO original is about $250. You could also, pull it out your self, and probably repair it with just some rubber hose.