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Strouty

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Blue Burb news….

Ran the truck for a few hours, let it sit for 45 minutes, went to get data on long crank with the tech 2, except it started right up.

I had theorized that the starter may have been the issue, but man, I wouldn’t have guessed after we did all the other testing. At this point the working theory of why it wouldn’t start is because it was slow cranking just enough that the injection pump wouldn’t catch, by pouring water on the pump, it would tighten up the tolerances enough that the slow crank would still start it. Basically mimicking a worn out pump almost exactly. Of course I am sure there is just another issue around the corner waiting to stump me. I am going for a couple errands, will be turning it off at each stop to see if we get anymore of the long crank nonsense. Maybe I have fixed it, I hope so.
 
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Strouty

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The good thing is that we really only changed the crank position sensor as a consequence of the parts cannon, the rest of the stuff was more we didn’t trust the PO and it was better to be safe than sorry. Injection pump was leaking, so it would have had to come out anyways. Overall I learned a lot and I am sure I will continue to learn a lot as I get to working on more of these.
 

harley jim

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You know my superduty will act like that at times,
when I make a lot of short trips around the property or go next door it starts pulling the batteries down and I have long cranks or a no start.
So I either charge it or take it to town to charge it. Then it starts fine.
I hope that's all that was wrong with it.
 
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Strouty

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You may want to at least clean the terminals.

The Blue Burb is still starting great, I started actually looking at things and I have owned the truck for 9 months, but have only driven it 1600 miles, and 300 of that was a trip back from Connecticut. No wonder I couldn't get things figured out, the truck wouldn't let me put any miles on it, I usually have much more seat time than that, had it been running right, I would have probably put about 6000 miles on it in the same time frame, maybe more. Instead I had to drive the F-350 around most of the time.

My fingers are crossed that this is the last hurdle on the drivability front, next is to fix the radio, install new lights, mirrors, and get the leak on the transmission fixed. I think I need a couple more days, so let's just say a week worth of effort to get it were I wish it was back in 2021.
 

xtremek

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Great news on the starting. Is fixing a radio worth it, or is it better to just replace it? Most of our older vehicles have Alpines in them. Has almost everything you could want (no back up screen ), hands free Blutooth, USB, front aux jacks.
 
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Strouty

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I was just being generic, there is something wrong with the factory amplifier(s) and basically the radio turns off after 10 or 15 seconds. I either have to replace the bad amplifier or bypass it by either jumping around the existing wiring or installing all new speaker wires directly from the known good aftermarket stereo I already have installed. I also have to replace the speakers, they are torn in a couple places.
 
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Strouty

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There is still a laundry list of things to do to the blue Burb, most of it got sidelined while I searched for the other issues, after this week, if it is still fully operational, I will start in on things and really get it set for me to be using as a daily driver. I am kind of excited about this, I guess it is easy to get excited after 9 months of disappointment.
 

bowtiguy

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@Strouty, until I did a search on that pump I didn't realize it was under the intake. Must have been designed by the same engineer that put the starter under the intake on the 1990-95 Corvette ZR1 engine.
Bob, as long as you don’t hose down the engine and the drain hole in the back of the valley isn’t plugged by Mickey, those LT5 starters live a long life. Contacts can get a little crusty. I’ve rebuilt (2) now “ while I was in there”. Plenum pulls are MUCH easier after placing a couple of 1/4 NPT pluggs for the coolant holes in the lower injector housings.
 

walrus

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So the starter wasn't turning the engine over fast enough to restart when hot? I find mine likes the glow plugs even when warm, no issues with glow plug circuit?
 
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Strouty

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It appears that way, definitely not a glow plug issue, in fact the advice given by others for this type of hot start issue is to bypass glow plug system to shorten time they were on. I actually pulled one of the glow plug wires off by accident, then forgot to hook it back up, so I only had seven glow plugs now. It didn't even rattle yesterday morning, it started right up, I still hope I can get the wire back on, the engine was too hot yesterday (when I remembered it) and it was the rear one by the turbo.
 

xtremek

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After chasing something like you have for 9 months, getting excited is an understatement of how I'd be feeling. Congrats on not giving up, and doing the hard work, even if you just happen to stumble across the answer. Looking forward to seeing you tackle the next issue with such determination.
 
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Strouty

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The worst part is that I really wanted to do the rest of my testing, it would have been interesting to prove a few things rather than have the problem go away like this. I did clean up the battery connections, so in my head I was thinking, could it have been a ground issue? I also put a new end on the cable going to the alternator and then the replacement battery cable that goes directly to the solenoid on the starter. I feel fairly confident in the solution and it makes sense, but had I done the ice or freeze test, it would be more satisfying to know it wasn't an electrical gremlin at the pump. Not that I can see how the power to the starter could influence the pump in any way, but the grounds could, at least I suppose. The only sensor that is still at play that I think could even possibly have caused this issue would be the stepper motor on the injection pump, it was the only plug low enough to actually get wet when water was poured on the pump.
 
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Strouty

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Walrus, how would you correlate the water with the grounds, starter, battery cable, curious if you have any theories, another one of my friends has a theory, but I don’t like it. ;)
 

mybigwarwagon

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It is possible that the wear in the pump is just enough that when it is hot the bad starter would not overcome it. Cooling the pump let the starter push through it. You may get to do an IP yet.
 
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Strouty

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I didn’t change the injection pump, just the power cable and tightened up the studs on the starter.

If you mean when we did change the injection pump originally, my theory behind that is that it is warmer out now. I think this would have been the same outcome with the original injection pump had we not changed it.

There are too many variables at this point, it wasn’t like I had an obvious gotcha moment.
 
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Strouty

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One thing that is clear, it wasn’t the timing of the injection pump.

I had never really gotten to drive the truck, much, I don’t remember all the circumstances, but on top of that, the more I drove it the worse the loose connections on the starter would have gotten, like a slow speed decline, the one time I drove it enough to actually have the no start scenario was a wicked cold night on the way back from Connecticut, but it was so cold, I left the truck running the entire time. Pretty much every other trip was just a fifteen to thirty minute trip, plus for the first few months it had thermostats that weren’t closing, so the engine never even got hot, I almost forgot about that.
 
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Strouty

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I really don’t want to try and map things out on a timeline, but I bet it would show that things were masked during the hot months by the thermostats, then it got colder, then the truck had one problem after another that sidelined it. Talk about a mess. :(
 
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Strouty

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Jeez, apparently I am making **** up. I didn't buy the burb until October 15th, I don't know where July came into play??? My Cousin and I were talking about it and he went to get it with me, apparently he thought it was July as well. Now it makes more sense as to why I didn't have heat related issues. That makes me feel a bit better too, it has only been six months chasing problems. I remember I didn't do much driving or errands with it because I couldn't lock it either, mower locks were messed up so badly, the key felt like it would snap off trying to unlock it. I also remember that it had some issue when I was going to take it with us when we went to knock down the tower, that was December 1st, ended up having my Brother drive his truck. I fixed the locks shortly after that, then there was the fuel tank fiasco, then the injection pump, right after that it was down for the radiator, then it was something else, but I will also say that I did drive it more than I remembered, the registration says that it had 347,800 miles on it when I registered it, currently it is at about 351,700, so almost 4000 miles. It was almost all local, I remember bitching about the mileage and not wanting to risk a road trip due to not trusting the burb. It has only gone 600 miles since the January inspection sticker, that is definitely less miles than normal. So the cold definitely masked a lot of the symptoms, especially with the help of the bad thermostats. I think we are on the home stretch, almost all the other issues have a consistent problem that is easy to troubleshoot in comparison.
 
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Strouty

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I figured it out, July 15, I went to Long Island to pick up a truck for my Brother, that is why I was confusing the trips, almost identical, we even used the F-350 to go get it.
BE913DC9-10BE-42EE-8D8D-9F707CCB7374.jpegAADC8B5C-8BBC-4090-BB4E-4895AAFB2955.jpegDC9C26B2-B178-4715-9762-E38643392C40.jpeg604799C7-FF23-4A3A-AF33-C487B645D719.jpeg
 
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walrus

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Walrus, how would you correlate the water with the grounds, starter, battery cable, curious if you have any theories, another one of my friends has a theory, but I don’t like it. ;)
coincidence :) Not sure as I doubt water helped any electrical connection. I'd have to see wiring diagram but starter draw could take down glow plugs if there was a bad connection that developed during a warm start.
 
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Strouty

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The glow plugs are a weird thing, I think the wait to start light always goes, but when the PCM senses the ECT at it above 125, it actually shuts them off or they have a very short cycle. I have found that the engine only needs 100 RPMs to start when cold, but needs 150 RPMs to start when hot. I did get to witness what happens on the scan tool and the culprit was always the timing was too low, it would want 14 and it would only get to 9. So at this point I would say it could have been the stepper motor, but I would think it would cause other problems after it was started. Once running, hot or cold, the timing was on par with what the PCM was requesting.
 

kaymccampbell

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So, the starter connections were bad, and dimmed the glow plugs, like Walrus said. Then cooling the injection pump, would reduce the clearances in a so-so rebuild, resulting in higher injector pressure and better atomization, and somewhat compensate for the partial loss of the glow plugs. It works. It's why we used to crank the pump pressure on tired/undersized Detroits for customers too poor/cheap for anything else.
 
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Strouty

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Here is a very basic diagram of the wiring, the only loose or bad connections I found were on the starter end, nothing at the batteries.

0A5E1C1B-4C09-4017-89E3-0A4E5E4A56A9.jpeg
 
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Strouty

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Also, I have another burb that has had as few as two glow plugs functioning, it had to be plugged in around 40 degrees, but once it was hot it didn’t need any help to start. It still only has five glow plugs and once it starts, it is still fine. I just don’t see how even bad glow plugs would cause the issue when the engine was 130 degrees or so. I am going to test this by disconnecting my glow plugs completely after getting it started, that should answer this question.
 
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Strouty

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Everything was selling really well, right up until my trailers. :(

I am now not doing well and only one item to go.

At least they are gone, but I would have been better off selling the black deck over on my own, it only brought $1300. Overall I am not too bad, but about $2k under where I wanted to be, hopefully my last item will do better, but I doubt it.
 
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