94 7.3L IDI will not start - Ford Powerstroke Diesel Forum
7.3L IDI (Non-Powerstroke) Diesels Technical discussion of topics related to vehicles powered by the 7.3 Liter In-Direct Injection Navistar engines.

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Old 07-29-2008, 07:00 PM
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94 7.3L IDI will not start

I have a 1994 IDI factory turbo 4X4 Manual transmission.
Three days ago I parked my truck everything was normal, yesterday it will not start just cranks, no popping,no smoke, no trying to start, nothing but cranking over and over and over.
I live in central CA so cold weather is not the problem (100 degres)
Both batteries fully charged
after reading other threads most advice was a bad relay/glow plug controller, so i replaced both also replaced fuel filter and air filter I filled the filter with diesel. Still nothing but cranking, won't start, pop, snort, or anything. Today I pushed in the valve on top of fuel filter cranked it and fuel came out, so then I installed clear lines from filter to fuel rail(grey lines it is IDI) and from fuel rail to injector pump. Iused longer lines with a loop in them. Cranked it over fuel came into both lines but never filled them up. There are sites for adjusting injector pump but they state it is for preformance. Mine is not preforming at all. please do not give me advice like Dump your IDI and get a powerstroke.This is my truck and I love it, and do not have the money.
Any advice on adjusting, or tweaking, or repairs would be nice. I spent all my money on the selonid and controller. one glow plug bad #5 cylinder (drivers side front) did an ohm test on them all and checked wiring harness & connectors with a DC meter all ok Thanks
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Old 07-29-2008, 07:06 PM
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Is there some kind of kill switch that could be bad?
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Old 07-30-2008, 01:17 PM
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did a flow & pressure check. Removed the top front spade from injector pump, removed valve core, installed tubing into a measuring cup. Pumped out 1/2cup in 10 sec.
So passed, pressure test 4lbs low end of the specs. I know you can turn up your pump, has anyone done this? Still pondering cracking the hard lines at the injectors, right now i have no leaks
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Old 08-01-2008, 03:34 PM
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I cracked the lines at the injectors and no fuel, i checked agin the fuel shutoff (FSS) jumped it and turned on key click click, back one also. So I removed it. Big T shaped crack in it. Anybody worked on the FSS? I will try to get a new one. Are there any fuel diagrams for IDI 7.3 on the web?
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Old 08-02-2008, 11:55 AM
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i will look around for a diagram but i havent ever seen one
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Old 08-03-2008, 05:21 PM
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No Start

Sounds like you may have a leak in your lift pump. When you say you have fuel at the filter, does it have a good healthy spray at the shrader valve or does it just dribble out? It should spray pretty hard. I don't know the exact pressure it should make, but if the lift pump doesn't make enough pressure, the injector pump won't work at all. A bad lift pump will also allow the fuel to bleed out of the line between the lift pump and the fuel filter, making the engine extremely hard to start since it has to fill the line every time it sits a while. I have had 2 or 3 of these go bad on my 92 IDI.

Just another idea for ya, but I think your on the right track checking the FSS also.

And as far as turning up the pump, it generally involves removing the triangle shaped side cover on the pump and adjusting the allen screw a few flats. All this does is increase fuel flow at Wide Open Throttle, so I doubt turning the pump up will cure your current problem. But it sure makes bettsy move a lot better when it is running, I know, my fuel screw is bottomed out in my IDI.

Good luck,

Pete
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Old 08-04-2008, 08:03 AM
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Replaced lift pump, 6.5 psi, fills a cup in 10 sec. found a new solenoid and new return lines & caps Just waiting for them (ebay). I had cracked the line at the IP, lots of fuel, tightened it cracked Hard line at injector NO FUEL.
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Old 08-04-2008, 02:31 PM
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No start

I would guess the new FSS will probably fix your problem, but if not, you may have to have the injector pump tested. That may be a problem, depending on your local injection shop. The shop in my neck of the woods won't even test rotary style pumps because when they fail it damages their machine.

You can get rebuilt pumps for around 350 bucks if it comes to that.

Good luck
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Old 08-07-2008, 09:53 AM
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Received New return hoses & plastic caps. I have a crossover hose (2 caps have a tee connector) New ones are 4ea straight conn. & 4ea elbow conn. no tee conn. mine are the new style with the conn. offset the plastic cap, not through the middle.
Should I use my two old caps w/ the tee conn. or use all new without the crossover, what is the difference?
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Old 08-08-2008, 11:22 PM
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Quote:
Originally Posted by Broncoguy View Post
I would guess the new FSS will probably fix your problem, but if not, you may have to have the injector pump tested. That may be a problem, depending on your local injection shop. The shop in my neck of the woods won't even test rotary style pumps because when they fail it damages their machine.

You can get rebuilt pumps for around 350 bucks if it comes to that.

Good luck

Sounds to me like they just don't want to test them. Unless their stand is comletely different than the one at the shop I work at it won't do anything to the stand if the pump doesn't work.

manurehappens have you tried taking the top off the injection pump and checked to make sure the shut off solenoid is working? Cycle the key and it should move the arm back and forth.

You can also try cranking it with the top off. It will spill some fuel out so put a drip pan or something under it but that will bypass the shut off solenoid all together and let the metering valve open up. If still nothing it could just have a worn head and rotor. Also this will give you a chance to take a look in the pump to see if there is any junk in there. If it's the original pump it could have the original flex ring on the weight retainer which are known to go bad and come apart sending plastic pieces all through the pump.

On the test stand we run 5 psi to the pump so if you have at least that much it should have enough pressure.
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