I bought a 94 2500 6.5l manual 4x4 turbo diesel just over a week ago. This is my first daily driving diesel and when it starts everything seems good. I've already put two brand new interstate batteries in and replaced the used and relocated pmd. The service engine light hasn't come on while driving since. It starts effortlessly in the morning or once it sat for over an hour, it also stops for fuel and starts back up just fine. My problem is starting when it is all warmed up and has sat for about 20-30 minutes. It usually cranks but no igniting, it tries once then just cranks. My starter is now giving me problems but I want to fix the warm start issue first. I can here the solenoid click on then I hear what I think is the pump being primed. When it does start, and it always does in 20-30 minutes, it runs strong with no hesitation or stalling. Any suggestions on where to look are much appreciated.

 

What you are describing is the injection pump (IP) is wore out next time you go for a drive take a bottle of water with you and when it fails to start pour the bottle of water on the injection pump and if it fires up you will need to replace the IP pouring water on it's a temporary solution it's not a fix.

The starter issue is due to the excessive cranking when these 6.5's are running like they should it will never take more than 5 seconds of cranking to start my 93 will start in any temp in less than one second my glow plug cycle is the longest part of starting the truck, from now on on no more than 10 seconds of cranking then let the starter cool at least one minute will prolong the life of a starter.

 

Thanks for the info, the fuel cutoff solenoid was getting very hot. A bit of water on the unit and time seemed to do the trick so I pulled the plunger out and she wouldn't start. After unplugging it and turning the ignition over a few times it starts just like it should. With a new starter it now starts like a new rig. I was originally looking for bad wiring, thanks again for pointing me in the right direction.

 

I had this problem. Turned out my batteries were both bad. I was told by the original owner they had been replaced recently.

I know you said that you had new batteries, but one might not be good, or the alternator is not charging them properly.

Every time you start the engine it drains the batteries, which in turn need X amount of time being charged by the alternator to return to proper levels. Bad batteries need more X to recharge.