I have a 1991 7.3 IDI and it was running but kind of rough, real hard to start. I pulled all the injectors, to clean them out, one at a time so I would not get them mixed up going back in. My return rail was leaking real bad so I also got a rebuild kit for the rail now no leaks, but no start. I tested the glow plugs and found 3 bad plugs, replaced all 8, now plug light stays on 10 seconds like it should but it took about 3 weeks to change plugs and clean injectors so I think I have a air lock somewhere and I cannot find it. I got the truck to pay a debt so I only know some of the history - farm truck, bought at auction for another farm, given to farm hand in place of pay (he knew NOTHING about diesels), gave it to me to pay a debt ran OK for 3 years. Fuel Pickup in one tank is broken at 1/4 of tank seems to be a common problem in old IDI trucks. Second tank is OK and has more than 3/4 fuel, still seems like I am starving for fuel. What next?

 

If it has a mechanical lift pump did you replace that?

 

I did not replace the lift pump, I took the filter to IP line off and cranked the engine and got plenty of fuel out lift pump works!!!!

 

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My father in law and brother in law each had a couple of old Fords about that age and I know they were forever having trouble with the injection pumps. Between that and glow plugs I think they got tired of them. Good Luck.

 

Anything so far ?

 

How long have you been trying to start it? Replacing the injectors and return lines will allow a lot of air into the fuel system and will take some time to get it fired back up again.

 

I usually prime mine with ATF , usually fires right up , of course i have my foot to the floor too ... never dies , close a few times ..LOL, then takes right off !!!!