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Hard Cold Start; NOT GLOW PLUGS!!!
I'm new to this forum, but after sifting through all the forums I could, I still can't find a solution to my problem.
I have a '99 F350, it won't start unless I have it plugged in, even when it's 60 degrees out. I have replaced the glowplugs (motorcraft), Glow Plug Relay, Under Valve Cover Harness (both sides), injector O-rings, fuel filter, coolant, oil, and cleaned the IPR. Yes, the Glow Plug Relay is working and I've checked the resistance on all the NEW plugs, they all test fine. If the truck sits for a while but doesn't completely cool off, it will start but run rough; If I put the accelerator down to the floor it will slowly build RPM(over 10-15 sec) then around 2,500-3,000 RPM it feels like it 'blows something out' and will run fine after that.
Sometimes it will start, run really rough, then die. If that happens and I try to restart it right away, it will do a little 'skipping-almost-start, but as soon as I let off the starter it just dies.
Even when it's plugged in and starts ok, it doesn't just fire right up. I will crank it for a second or two then it will skip a little and gradually start up.
I guess I should also mention that there is virtually no smoke during startup. No white, black, blue or any other color. There might be minimal smoke, but hardly anything
I Have Auto Enginuity and have monitored the ICP and IPR Duty cycle, both seem ok; the ICP starts at 507 and then builds to about 2300 PSI over the course of a couple of seconds of cranking. the IPR duty cycle starts just under 15 then goes up to a high of about 43. I'm no expert, but those numbers seem to be where they should.
I did an injector buzz test (engine 'cold' but plugged in) 1,2,3,6 buzzed nice and loud; 4,5,7,8 buzzed not quite as loud.
I know that with it starting when it's plugged in really points to a glow plug issue, but I can reasonably assure you that it's NOT the glow plug system. The problem is: I can't think of what else would be temperature related.
I'm completely stumped on this and hate to just throw money and parts that aren't needed at my truck. Any help would be really appreciated!