[Pierced]

I have searched and searched for info on this problem and I am hoping someone here can point me in the right direction.

I recently (2 months ago) bought my first diesel truck 1994 Extended cab dually with 6.5 turbo and NV4500. I bought it from my neighbor not running, he said he changed the fuel filter and it never ran again. I primed the system and after cranking on it for a bit it started up. The thing thats bugging me is thats its very hard to start.

I replaced the lift pump, glow plugs, fuel filter, FFM, Fuel heater, WIF sensor, Air filter, And a new pmd with remote mount kit(behind bumper). This thing is still hard to start whether its cold or at op tempature. I fill out the diagnosis check list and hopefully someone can help.

Thanks.

Pic of the dually and my bagged truck.

1. Describe the problem you are having in detail:

Hard starting when engine is cold or operating tempature.


2. Year of truck/engine.
1994 C3500 ext cab dually 6.5 Turbo Diesel with NV4500 Transmission

3. Odometer reading (indicate miles or kilometers).
149,xxx miles

4. Indicate the model number on the Injection pump (starts DS4 or DB2......).
DS4

5. Indicate if you know if it’s a 1500, 2500, 2500HD, 3500, 3500HD.
3500

6. Do you have an EGR on the engine? (An F or an S engine code 8th VIN digit)
no

7. Air Filter condition (visual check).
Replaced within last month.

8. Fuel filter condition (freshly changed, mileage since changed).
New fuel filter withing last month along with FFM,WIF sensor, and fuel heater.

9. Location of PMD/FSD? (ex. on pump/remote over intake, behind bumper).
New PMD 11/19/12 mounted behind bumper.

9a. If remote mounted, describe wiring harness (homemade or purchased from which vendor).
Remote mounted harness from ebay sell Angelofish

9b. Indicate the location and condition of the FSD/IP grounding wire.
Seems to be grounded to the intake, condition seems good.

10. Outside Temperature (C or F). 60°F

11. Service Engine Light while running?- on/off/intermittent
No

11a. Service Engine light does glow during start/cranking/bulb check: No

12.Have you scanned for engine codes? No
12a. List exact results on engine codes.
n/a

13. Condition of Battery terminals (removed, cleaned and tightened).
New terminals along with new 4/0awg battery cables.

14. Known condition and age of Batteries.
Good, about a year old

14a. Are batteries a matched set of same age?
yes

15. Condition of Major Grounds (removed, cleaned and tightened)
Cleaned and upgraded with 4/0awg wire and copper terminals

16. Does engine crank, or "turn over"?
yes

16a. Does engine start and run?
yes

17. If engine does not start- Crack injector line: do you have fuel?
Yes

18. Does your Wait To Start light come on?
Yes

18a.Number of seconds WTS light is lit.
6-7 seconds

19. Engine Cranking speed (if you have an accurate tachometer).
N/A

20. Are you experiencing Stalling?
No

20a. Describe the event (upon startup only, down the road, hit a bump, etc...)
When starting the vehicle

20b. Do you notice loss of dash or instruments?
Speedometer is not working but that is due to a faulty speed sensor on the transmission.

21. Check turbo inlet and air filter for obstructions.
clear

22. In a no-hot start, pour a bottle of room-temp water on the injection pump. Does it start now?
n/a
23. Lift pump test - Describe results.
Engine idling, open t valve engine dies, replaced lift pump getting the same results.

24. Upon cold start, does the radiator hose get hard quickly?
no

25. Upon cold start, do you have excessive white smoke?
no

26. Do you have excessive cranking time before the engine starts?
yes

27. Have you used the block heater? Does it affect engine starting? (only try for starting problems).
no change with or without block heater.

28. Are all glow plugs in proper working order?
Yes all new plugs within last month

29. During hard acceleration, do you have excessive black smoke?
no

30. Do you have any unusual exhaust smoke issues?
no

31. Turbo check out - Pass

32. Indicate fuel that you are using: Bio-Diesel, #2 Diesel, SVO/WVO, other
Regular pump diesel

32a. If running Veggie Oil fuel setup, indicate details of your conversion (homemade or packaged system).
n/a

33. Are you using any fuel additives? If so, please list.
Lucas fuel treatment.

34. Upon unscrewing fuel cap, do you have a large vacuum formed in the tank?
no

35. Do you have any service history available that might pertain to the problem you are having?
no

36. Please indicate any modifications to the vehicle that might help us diagnose better.
Completely stock other than the remote mounted PMD.

 

[JSarge]

When you say hard to start, do you mean it seems to be cranking slow or is it cranking consistently and takes a while to finally fire up?

If your starter is in rough shape, these engines will take a while to kick up. They appreciate an as healthy as possibly starter. If it seems the starter is healthy, i would check out your glow plugs. You list the WTS light does come on, so the controller is working- that doesnt mean some of the original fusable links haven't burnt out. Check voltage at all of the GP's, better yet, replace them.

 

[JMJNet]

23. Lift pump test - Describe results.
Engine idling, open t valve engine dies, replaced lift pump getting the same results.

Based on this answer, the OPS is bad.

Replace with ACDelco OPS only!!!!

Remember on 95- model year, the OPS controls the LP when engine is running.

Try finding an ACDelco OPS and replace it.
If it works, you may want to do the OPS Relay mod.

 

[Pierced]

Heres a video of how it starts.

http://youtu.be/kmDOnuYl358

Would the OPS still interrupt the lift pump even if the relay is bypassed like this?

 

[JMJNet]

Don't know I have a 95.

If you bypassed, does the LP turn on?
If yes, can you open the t-valve and see if it has fuel flow.
If you have fuel flow, can you start now as you shown in the picture?

If you still cannot start, the fuel filter installed may be bad.
There are a few bad ones lately.
My dad got one without a hole on the bleeder valve, etc.
Who knows what you get.

Or the filter bowl is dirty? etc.
Or the hose to the IP is clogged.

 

[Pierced]

That video is with the relay bypassed and LP running constant. I checked for fuel at the t with it running and the relay bypassed and I got fuel there without the engine dying.

This is making me crazy lol.

 

[JMJNet]

As I said, OPS is bad.

See Post #3

 

[Pierced]

As I said, OPS is bad.

See Post #3

Replaced the old OPS with a new A/C Delco OPS today and it still starts hard.

 

[PrivatePilot]

Have you verified that all eight glow plugs are actually getting voltage?

What brand of glow plugs did you install? Also, it's somewhat hard to tell in the video - How long does the wait to start light stay lit before you start cranking?

I don't doubt that you have a lift pump issue as well (OPS as JMJ mentioned) but if it was overridden when you took that video it would seem to be a heat issue based on the way that it does eventually start just fine.

 

[BIACS]

Batteries test good? It takes a lot of oomph!

Also my starter was shot from a dying IP. So hard cranking can get a starter worn enough to at least be jussst too slow not to crank fast enough to start.

(get the stock unit rebuilt though most replacements are junky off the shelf)

 

[racer55]

From the video I would not say it is starting hard,although you wait too long after the glow light goes out the first time to crank it over.

Item 9b of the list,get the IP harness ground back on the IP!
Under a OS screw is stock but anywhere it can have good clean contact with the IP is a must.
Pictures here show the proper location:
http://www.mamut.net/royh/newsdet9.htm

Has the IP ever been changed?
Was the electronic timing set properly?When my truck had late timing it started slow.ran hotter and was lazier than it was after getting the TDCO relearn and corrected.