Fuel Starvation Problem

So did you remove and discard the fuel heater while you were in there?

That is ample evidence to me that you do have an algae problem and need to drop the tank.

 

I see lots of rusty flakes too, so water is also present in the fuel.

 

After replacing the pre-filter strainer, I road-tested the truck and the results are good. The engine motored up some long, uphill grades at nearly full power and it didn't hiccup, shudder or stutter. I also cleaned the old fuel strainer for re-use perhaps at some future date.

The fuel heater assembly remains intact. I think its function is to heat the fuel so that it passes through the pleated paper filter. Maybe it doesn't heat it enough because one time I was caught with Summer fuel in the engine on a particularly cold December morning. The engine stalled out during a long, downhill descent because parrafin accumulated in the pleated paper filter. I had to hand-operate the transfer pump to force fuel through the filter in order to get the engine re-started.

My pre-filter strainer has not been touched for 24 years and 66,000 miles because I didn't know it even existed on the engine! I have a Cummins service manual but it doesn't mention any pre-filter strainer maintenance. Maybe it's only applicable to Dodge Ram.

 

The fuel heater is a worthless appliance that is the cause of many air in the fuel non-starting issues. You've been warned.

 

^^^ What he said.

 

YEP get rid of the heater as they typically go bad anyway. Did you run some old 2 cycle oil?

 

I'm not sure what 2-stroke engine oil has anything to do with a Cummins turbodiesel engine...

 

You would wonder how many oldtimer "recycle" their used engine oil in the fuel tank of a Diesel engine...

2 cycle - first lube oil, then fuel oil.

 

And no, you shouldn't do that on a modern engine.

 

I ran some 2 cycle oil that was on the Farm. Turned out it had gotten old and every 3k or so my fuel filter started clogging on another 12V I owned.

 

This can't be a good idea.

 

@Dylan Thomas, Another thing to put on the maintenance list for sure! Sounds like you need to get the fuel heater plug and delete that from your truck. Also need to get some PS anti gel to put in when winter rolls around to avoid the "gelling" issue. I have a 100 gal transfer tank on my truck and treat the fuel at the end of season due to fuel change over. So far so good on that program. When you park your truck for an extended time, try to keep tank full to avoid condensation. Glad you got to source of the problem! Keep that ruck running!

 

There isn't a "fuel heater plug". You simply remove the heater and screw the filter bowl into the hole that is left behind. There is a short wire harness to delete as well to clean up the job.

 

https://www.genosgarage.com/product...eater-blockoff-gg-fhbo/fuel-heater-components

 

This is the 12 valve section. The OP has a 12 valve. !2 valve Cummins are not the same as '98.5 - '99 24 valve engines. They do not need a plug.

 

Thanks. I added a couple ounces of Biocide to the fuel tank and topped up its fuel level. Not sure what PS is but I'm interested in some kind of fuel additive which would eliminate any water in the fuel. I wouldn't add any additive.

 

https://powerservice.com/find-my-product/#2

https://powerservice.com/find-my-product/#1

 

If you don’t drop the tank and clean it out, this will happen again.

 

That's for sure, if it is so bad that it plugs the filters and strainer the fuel needs to be discarded. The tank flushed with a biozide and refilled with clean new diesel and a massive amount of biozide again to kill all the germs inside the lines, filter assembly pump.
There is no shortcut here, it needs to be done following the rules.

 

Best carry a spare filter!!!