The pump is on the passenger front of the engine on the bottom. I doesn't take much psi to run them 8-10 psi should be enough. Try undoing the solenoid to at least prime the system and see if it cranks better. I don't know if you got the rest of my post strange I can run CNC machinery but can't use my computer at home. When you take the lines lose you should use a tubing wrench if you got one. If not a normal open end will work just be careful if it looks like it is rounding out stop. You can spray something on them put a short cheater pipe one it and make sure only the fitting turns and not the line or injector. You're welcome and let us know if it starts and if not will figure it out.

 

Hey there , thanks for getting back to me , No I didnt get all your message but I guess you just finished it :-) I am going to look tomarrow for the fuel pump , I know I got fuel all the way up to the lines coming from the injector but after that going into the motor I couldnt tell u I cant crack the lines, I am busting my guts trying to , and I know not to round those would be HORRIBLE but my luck It might happen.

I sprayed some wd-40 on them all to let it sit over night , and hopefully tomarrow I can crack it all open. I got a test light YAYYYYYY, the truck burned it out no matter then 3 minutes out of the package. went and bought new bulbs for it , burned them out too, the system seems to be running 24v to some things like the solenoid for the glow plugs , BUT I was able to confirm power to the Injection Pump , I was able to comfim power to the glow plug BUTTTTTTT and a big one , the solenoid Is not cycling the plugs are staying on constant , so could that be the solenoid or is that the doo hickey on back of the engine that does the whatchama call it with the glow plugs HAHAHA I think it cycles the glow plugs its a thing in back of the engine that has all the wires sticking out of the back of it , The proper name actually escapes me, so I am sorry ..

As for a test light , what else do I need to test , I think I need a light that can handle up to 24v and this light definitly is not cutting it, its actually costing me money , like the darn truck LOL ...

But , I really do appreciate all the help , now I have to just crack the lines and do a little voodoo chant on it and pray it starts ...

 

If the relay is keeping the glow plugs on they are burned out. They are 6 v glow plugs and more than 6 of 8 seconds will do them in. That might be why it won't start instead of not getting fuel. Also have the parts place check the number of the test light b ulb. It might also be a 6 volt bulb. If it is get a 12 volt bulb for replacement.

 

They're not 6v plugs, IIRC. They're 12v, but a slow glow. On first start up, the light will deluminate after 8-10 seconds.

 

Is this a old military truck? If so it would have a 24 v system on it. If so that might be your starter problem. Are your batteries series or parallel I don't know if you know how to tell both neg. to ground is parallel 12 volt, neg. to pos. series and 24 volt. I figured you would know not to round the fitting off but I figured I would say it anyway because I spend a lot of time fixing peoples I didn't knows and messing up an injector line could be a big problem. I don't know if you can buy them new. As for the glow plugs staying on all the time that could be bad. Yes it think the do hickey watchama call it does control the glow plugs. I went out and looked at mine and the white wire was cut on it I think it is your glow plug wire. I forgot that on the 6.2 they run a separate solenoid on the wheel well you can bypass the auto controller and put a button on the dash with that solenoid . It has a sticker above it that say's it's controlled automatically and by passing it may cause glow plug failure HA keeping it stock may cause glow plug failure. They go out and a lot of time the glow plugs stay on thats bad. In the short life of the light you where getting power to the glow plug it-self? Do you have a Ohm meter? if so check Ohms between the spade of the glow plug and the ground. I think it should be ether 4 or 8 i can"t remember if it's 0 you know there bad and then it probably get's worse from there. Try pulling one out my guess is there melted over if they are they won't come out easy. The only way I have ever been able to get them out when they are like that requires a magnet,injector socket and a long punch. I dont know if you have a injector socket a normal socket won't work but there not hard to come buy it's just one more thing. Take the injector out which means guess what, you have to get the line off it. You can see the glow plug through the injector hole roll the glow plug around till it points up in the direction it is bent, put the punch on the end of it and attempt to straiten it most likely it will break off don't worry it just falls into the pre chamber, pull the glow plug out and go after the tip with the magnet, if it falls all the way down in the cylinder that calls going to have to be yours I have had them do that before you can't get it out without pulling the head I just put it out of my mind and start it up I know it scary but apparently the piston just pulverizes it I am not going to tell you to do that you make that call. repeat that all night and it should be ready for new glow plugs but if you got a 24 v system I don't know if you can run parts store glow plugs. If you want to make them manually operated let me know and I can look at mine its a 83 also and tell you exactly what I did. No problem helping its getting hard to find any one who knows any thing about the 6.2. The lines are tight put a cheater pipe on the wrench Do your voodoo chant and pull like hell,tell me how it goes. And just remember you can darn near fix everything on these trucks for the cost of one payment on a new one. I don't know about yours but mine gets heek of good fuel mileage not very fast but a 25-28 mpg I get over it pretty quick.

 

Hey there :-) Is this a old military truck , No. This used to be a old city water truck(still has pto and pully system on the transmission), they took the bed off put a new one on, not a single scratch, not a single inkling of rust on the truck or anywhere underneath the truck, matter of fact the truck still has all the factory motor stickers and all the factory info plastered all over it .


But the batteries, Im almost positive there running in series , but I know there connected to positive to positive but the ground I did not look at, Im pretty sure its running 12v I just think this test light is a bad light, Im taking it back tomarrow.

The glow plugs , yes I do need a ohm meter , Yes there is power going to all the plugs, but how much I dont know , But I do know for a fact that I havent once left the truck on since the glow plug disaster for more then 10 sec with the key on, and my fingers crossed that the plugs are fine, but what I read above they might be trashed , which is possible. So when I get the ohm meter I will check that also, and Grady did make a good point that it might not start due to the plugs, but I smell the fuel burn, I even threw a tiny tiny TINY shot of wd-40 into the manifold, nothing.

As for the starter , LOL I know its trashed, I looked at it the other day and from messing witht he motor trying to get it started it smoked more then the truck LOL not to mention the solenoid broke off of it on its own LOL its dangling from the starter . The starter is throwing a good crank into the engine, but Its draining the batteries something fierce, I have the equipment to test the batteries and test the charging systemso honestly thats not that huge big deal , BUT for 125 to 230 dollars for a starter it actually is a big deal LOL stupid me ... What happened to the 40 dollar starters, been so long since I changed one ..

Cracking the fuel line , well I have already tried the whole cheater bar and wrench they just wont budge so like I mentioned before wd - 40 and some vood doo chants and dances over night and hope it will make a difference .


The test light , garbage , its rated for low as 6 volts and as high as 12 volts BUT even just testing the battery it blew the light out . The light got super bright and it fizzled , HAHAH all these problems I brought on myself looking for the vacuum pump and replacing the broken line from the filter to the injection pump , I just cost myself , well I can find a starter reman, $90 after core, $16 for glow plug solenoid, glow plugs I think I got quoted anywhere from $60-90, But any preferences or suggestions on a good brand ?

The doo Hickey Whatcha ma call it I was refering to in previous post, is the Glow Plug Controller !!!

Is that the one that tells the solenoid to turn on and off and cycle the plugs ? And 2much junk, FYI the white wire on mine is also cut

So Tomarrow I am going to Definitly crack the lines, check the mech pump, get a ohm meter and check the glow plugs, return the test light LOL get a new one, and the starter can wait until I get this all figured out , Oh and order a new solenoid because I had NO out going power coming out of it only going in from battery.

I think thats it, Any suggestions or ideas of anything else is always appreciated and I will definitly respond by mid afternoon the progress , Once again thank you all very much for helping out, I could do it with out you all and your knowledge. Mike


1 More thing , I forgot to mention this and while on the whole fuel subject, when the truck was started and running, before this snafu, she puffed blue a lot and I have 2 theories on this and tell me if this could be part of the fuel problem, Filter, needed to be changed, diesel fuel about 3 years old, No creepy crawlers in the fuel or alge or living things, plus I already added fuel with bio from the pumps and ran 3/4 of it through. I have been reading and from what I found out the glow plug controller can contribute to all this , but then again air in the fuel line, to much fuel to engine can cause all this from what I have been reading ...

Here is something that might assist in solving it , when I stepped on the gas she sputtered and sounded like it was back firing out of exhaust didnt do it all the time but after stomping on it normal idle wouldnt blow so heavy real light but still can be seen then you hit the pedal hard again and blue up the air around me . Now there is no fuel in the oil , no water in the oil , No fuel or oil in the radiator BUT she is consuming radiator fluid and I am assuming because the heater core is bypassed directly into the pump, doesnt over heat, So I dont know , while this is all pulled apart I figured I might as well work on this fuel air problem as well. Im sorry everyone , I do feel bad about throwing this all out there, and you all doing so much to help me does mean alot, Once again thank you all very much .. Mike

 

Light let me guess made in china? They can't make a light bulb but we want them to make everything else.

As for the starter I don't know how the solenoid is dangling and it still cranks good? You must be one of those people. The ones that manage to have the strange things that make no sense happen to them.

Tomorrow throw the cheater bar to it and it's nothing hernia surgery can't fix Just make sure the line and injector stay put. This thing must have never been taken apart.

I am pretty sure the thingamaboby controls the glow plugs but I think it also runs the fast idle. Tomorrow after work I will look at mine. I'm a woodlands creature and don't really fell like going out in the dark to look at it seems no mater how long I live in the woods don't like going out in them at night. It's been at least 13 years since I did anything with the glow plug controls on it and if you knew me you would now 2muchjunk makes perfect since for me. 2 6.2 and 4 6.5 and to many other ones to count things run together.

I would say there is a good possibility it is a glow plug issue but we know it had air in the lines so I would start by making sure there is no air in the line first. Burnt fuel smell don't necessarily mean the glow plugs are getting hot enough to fire the fuel. WD-40 probably would not fire off in it because it is a IDI diesel and before it got to the glow plugs they probably would have cooled down to much. Don't throw stating fluid to it most likely it would start but the risk of damage is to high on a 6.2. As far as brand of glow plugs I have always ran just plain ac-delco. There are supposedly better ones out there I have just had good luck with ac-delco. I just wouldn't buy the cheaps't ones out there.

Have you ever changed the fuel filters on the truck? If not I would do it with three year old fuel in it. I don't know if this is your first 6.2 but there should be two filters of it. A water separator on the fire wall and a actual filter thats a pain in the butt on the back of the intake manifold. Get a clear plastic bottle and open the bottom drain on the one on the fire wall then you have to open the top one and drain the fuel out of it in the bottle so you can see what is in the fuel and if it has water in it. Fill both of the new filters up with clean fuel and put them back on. If they are clogged or have water in them they do stupid stuff.

Has the truck always been low on water or does it use it up as you put it in it?

Don't fell bad about asking for help on your problems we have all been there how do you think we know what we do. I am sure we have thrown enough at you tonight also. Fell free to ask any questions you have I don't know every thing about 6.2 but after owning and working on them as long as I have you learn somethings about them and I am more than happy to help any way I can...Phil

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I guess you didn't get a chance to mess with it to day I didn't get to look at mine rained all day. let me know what you find out.

 

Im replying to your edit that you posted today :-) I sent a pm to you letting you know that I couldnt get to it today , it dropped from 40 to 20 degress and then a nice windchill pretty hard to kick up the cold even more , but tomarrow its supposed to be 40 degress again so if it get that high I will be out there with shorts on .

 

Al Gore's global warming is going to freeze us all to death.

 

LOL thanks grady ! Speaking of freezing though .... Everything I am doing this truck just came to a screeeeching halt ...

So why has everything come to a freeezing halt , well ladies, gentlemen, Diesel buddies of the world the starter motor ceases to exsist. OMG LORD HELP ME !!!!!!!!! So lets look on the positive note, to everyone that has gotten me to this pointI say thank you

I managed to crack the lines , but before doing that I realized I forgot to change the primary filter when I changed the secondary (secondary has the spigots on them, FYI) and I realized that it would be a lot better if I did change it and primed this filter , OMG Im a genius right yea well Im not that filter was half primed but the gentleman before me took the time to round out the OUT fitting that leads into the injector pump.

After monkeying with all that for the last hour I finally managed to get all that great stuff off and prime the filter yay. I managed to get it all back together and here is a big thing for everyone, for the last 2 days I have been running back and forth to get the right tubing wrench, its 3/4 for anyone who doesnt know, the darn wrenches are not cheap, BUT I cracked all the lines except one (i got a lil lazy) , im peeing diesel all over now YAAAAAAAY, but low and behold after a couple turns of priming or getting my truck all nice and wett mmmm I put all the lines back on and I got a whole 2 - 10 second turns before the starter says no more, she wont turn the engine over, drained my batteries almost dead again

Lets move down to the glow plug issue I havnt gotten a ohm meter yet, there is one in the house, I have to find it, I know the glow plugs have juice but I cant tell you how much I had really high hopes when the system was all nice and wett she would of kicked just enough to tell me she is still alive, but the devils duece (thats her name) dueced all over me.

So ladies, gentleman, Diesel bombers and enthusiests, My project is on hold until I find a starter. I have a price quote in but I dont think those companies in Dbombers want to talk to me , and then again , Im not paying 165-240 dollars for a starter, I know where to get one , and I have to order it tomarrow should take a few days to get it in.

One Question, all my guages volt, oil press, temp, stopped working today, im thinking its because the wires are sizzled at the solenoid ? any comments ? before they would jump when I tried to start the truck now they are dead, hope I didnt burn them out. if I did, its the story of my life.

Lets see anything else .......... lets see, glow plug solenoid on order, most likely need glow plugs, need a starter, need to fix guages now


Can anyone tell me since she was peeing at the lines I cracked on the engine going into the engine, am I going to have to crack them again ? any other preventitive things I should do while I gather everything up and put it back together ? any and all suggestions very welcome .. Mike (p.s) Phil sell me a starter HAHAHAHA or better yet FREEEEEEEEEEEEEEE ok i can pay for the box and the shipping !!