I have a 2000 E350 7.3, bought van last year it had a shudder. Took fuel system apart up to the injectors and cleaned system. Installed new fuel filter. Installed new pick-up tube. Pick-up tube disintigrated and clogged pre-filters in sending unit and replaced the I.D.M. It ran fine for a year. The engine would gasp for air now and then. A 5 chime 5 time warning would go off while driving from time to time. I know the turbo needs rebuilt. Recently it ran out of fuel, and eventually got it restarted and running. All was fine, then sitting in traffic it just died. Ran batteries dead, recharged, put more fuel in and it eventually started again, usually restarts after I open the fuel filter and cycle the key a few times. My truck has 2 different relay looking items to the left of the H.P.O.P. and fuel filter housing. 1 is behind the alternator, the other is behind #1. The rear or #2 relay (what looks like the glow plug relay) is smoking when I turn the key to on. Could that be my problem with why it shuts off? It needs an oil change, it the Fuel pressure sensor sticking?, Could that be my problem? Checked the lift pump, it sprays a 2' stream when I disconnect the line to the fuel filter housing. It does bubble and spirt a little before getting a nice steady flow. Put in a new fuel filter. It cranks, it wants to start, it just will not. I am about to go belly-up, from all the downturns to have affected my once middle class socio-economic status. I have very little money to get this thing running before I lose the rest of what I have left. My question is: What steps can I take from cheapest to expensive to figure out what the issue is? I have no specialty tools like fuel pressure guages, or items of the like, but I do have many standard tools and decent mechanical ability. If one of you could literally save my A%$ here would figure some way to repay you. Please!

 

Your glow plug relay should not be smoking... That to me is a concern...

Check the level of your HPOP reservoir. Gonna want to stick a straw or something down in there to measure how far from the top.

Make sure to check all your fuses as well..

 

Im with powersmoker on checking hpop level! Do you get any smoke while trying to start it?

 

When I was in traffic and it kicked out it dies like someone shut off the key and a quick puff of whitish smoke with a slight blueish tint. Then try to start it and I get another quick puff of smoke. Tinker a little, charge the batteries and it runs as if nothing is wrong. Then it just dies, like someone shut off the key again.

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How do I check the H.P.O.P. level? Where is the nut to gain access? And which of the 2 relay looking devices is the glow plug regulator? The one toward the front or the one toward the rear of the engine compartment?

 

In front of fuel filter take of the powerstroke cover and there's a sensor wit one wire take that or the star bit plugout

 

H.P.O.P. was full, almost to top, but the oil is a little gritty. Why won't this damn thing start? Tired of draining the battery, waiting for charge, then starting all over.

 

Bad batteries and alternators cause issues like this. batteries without the capacity to hold enough amperage to run the injectors (which run anywhere from 90-120v and high amperage) fuel lift pump, and supply all your glow plugs. a high amperage demand from these components (especially your glow plugs) can cause A LOT of heat through a relay, possibly causing your smoking glow plug relay concern. since it's been heated like that, replace it. it should be the one closest to the front of the truck. the other relay is for an intake air heater. have your batteries tested

As for the alternator, it sounds like it's not charging your batteries if they keep going dead. have that tested as well. go from there and let us know what you find.

do you run a fuel additive at all? what's the fuel filter look like when you pull it out?

CHANGE YOUR OIL Powerstrokes run on oil pressure!

 

The glow plug relay is the one closest to the firewall... The rearmost relay...

Are the batteries dying from cranking? why are they going dead?

 

Your profile says you are in Florida but that covers a lot of territory. I am in north Florida not far from Gainesville and have an autoenginuity package. If you are in the area I might be able to help you.

 

Yes the batteries are dying from cranking, once charged and the truck is running they stay charged. I am going to change the relay, cuz I KNOW it's smoking, I am going to change the oil cuz I KNOW it is bad. Will also suck all the oil out of H.P.O.P. and change that oil as well.

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Thank all you guys for your help so far. After charging batteries all night, they die after 5-7 cranks. Is that normal in a Diesel with good batteries? I will do the above in previous quick post. Check back later, if need be I will get new batteries.

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Also DieselDanBoy, I do not use any fuel additives. I just changed the fuel filter. The one I took out was from 1 year and 3 months ago. It was still whitish, the paper was slightly gray. I thought it was going to be dirtier when I pulled it.