Clogged IP return valve

[AECS]

I really need some good news guys.

2 days ago my M1009 just lost power. Had to floor it to get up to 35 MPH. Barely idled and died on me a couple of times at idle. Always re-started right up. while idling not much smoke to speak of, but after idling a minute or so, when given gas it made lots of white smoke, IP timing marks are lined up.

Fuel flow test proved good, 10 secs of cranking gave me over 1 pint of fuel at filter inlet, and 15 secs gave almost a pint after the filter.

Pulled the IP return valve and it seemed stuck, brake cleaner seemed to free it up after a while and a couple shoots of 20 PSI air. Not much came out, and what did was not black "coffee" grounds, more like red flakes, almost like dried lacquer. Could this be from sitting or bad fuel? I need to move across the country soon and don't have 3-500 for an IP.

 

[the skull]

Dude, all of a sudden mine is acting up too. I changed filter, drained and refilled tank with
new, different fuel, I'm going to look at the return lines tomorrow. But I think my flex
ring in the IP went south.
Side note, I did dose it up fairly heavy with TC-W3 and some Mobil-1, the fuel was kind
of oily, but 2 quarts of oil in ~16-20 gallons shouldn't be a smoker in these trucks?
Mine is an 84 1008, 27k. Ran good til now.
Well, 500 miles anyway, I've only had it for a few months.

 

[the skull]

Update on mine---
I cleaned my return valve and blew air through the return line,
that valve was stuck pretty bad. Truck rolls down the road nicely
now, no trace of that smoke and idles smooth. I'm going to drive it
and see how it goes. Good luck with yours!!!

 

[Warthog]

I would at least pull the top cover off the IP and see what is inside.

 

[the skull]

I probably will, I was just so happy to not have a giant
blue cloud in my yard I had to drive it down the road!
I have to run some errands this afternoon, I'll try to look
at it later

 

[AECS]

Will do that Warthog, it is running like a champ again, that is good, but I just have a feeling that I am sitting on a time bomb.

 

[the skull]

Gotta pull the top, drove it around & back to the house, back to 40 mph
and blue smoke, DagNab It! Busy tomorrow, gonna have to wait for more
diagnosis. Good luck AECS!

 

[the skull]

Ha! Pulled the return fitting out of the pump again.
Broke the (clogged) glass ball in the fitting. Gutted the
fitting, got the same kind of red stuff out of mine that
AECS did. Well, that truck has never run this good.
60mph no problem. And NO smoke. Is the red stuff
the fungus in the fuel? I'm just asking, I've not seen it.
If it makes the beer run tomorrow with no trouble I'll
take it to work on Sunday, that's a 50 mile round trip.

 

[Skinny]

Makes me think it's growing in the fuel from sitting or bits inside the IP are coming out. Something that was in the tank should have been filtered out before the IP.

 

[dependable]

Is the red stuff the color this shaft seal? There are other parts in IP made of this also. This is from a IP that left me stranded because I was in denial that I needed to replace it.

 

[the skull]

Kind of that color, but very fine and powdery. When the truck
acted up, I had almost filled the tank. After, I drained the tank
and refilled with different (new) fuel. Also a new filter. Generally I
drive it once a week, but no clue how much it sat around before.....
I'll take the top off of it next week
Thanks everyone

 

[AECS]

I dont think mine is, what I am seeing really looks like Shellac flakes, that you use to finish furniture with, kind of golden brown/ redish looking.

Before I pull the cover to look around, do I need a new gasket, and if so where do I look to pick one up?

 

[the skull]

OK, sorry in advance for asking, I can't find the post that tells me....
When you pull the top off the IP and put it back on, do you put it on
toward the radiator and push it backwards then put the bolts in? I really
don't want a smoking heap in my barnyard. That's what I did and
I'm afraid to crank it up

 

[Skinny]

I forget which way but simply pinch the return line if it runs away on you.

 

[the skull]

Got it. Picture 4-155 6.2 diesel manual. I had it, but paranoia had set in
after a tough 10 day stretch of fuel system frustration on this truck. Nothing
but fuel in the top of the pump, and even broke the factory seal on the one
screw on the top cover.

 

[schweigen]

I took my 1009 out after storing it this winter, started fine, drove it 150 miles, made a couple of odd trips around town but now it lost power suddenly and died. Put a new fuel filter, started and idled fine, got underway and same problem. Not sure if i should drop the tank an clean out the fuel tank or look into the IP. Any ideas?

 

[dependable]

Sometimes when I suspect I have a contaminated tank, I cut old fuel filter to see how badly clogged it was. If there are signs of alge, time to clean tank.

Another option is to blow back main fuel line to tank with compressed air, if it frees up fuel flow, it will probably be temporary and you may need to clean the 'sock' in the fuel tank.

Also, you can check fuel flow from lift pump. Crack bleeder on left top of fuel filter and put output tube in jar and check flow. If filter is new, and flow is good, it is probably the IP.