1572 Diesel Fuel System - Help Needed
 

Hey guys, I need your help. My 1572 Diesel (new to me) was running great when I tore in down to replace the driveline with a CV driveshaft a month ago. Glo Plugs are new, and I wired the Glo-Plugs to the Battery via a HD Solenoid. The temperature this morning was about 15F here, so it was on the cold side.

I never disconnected any of the diesel fuel lines or filters, just disconnected the battery and kept it charged. Wouldn't fire even with lots of battery. I opened the 2 bleed screws at the secondary filter, and nothing wa coming out. The fuel pump is running, but barely spitting out any diesel when I disconnected the line from eh talk. All my lines are really hard, so I'm heading out to get new 5/16" fuel line and replacing it all.

1. I was quite surprised when I removed the fuel tank to find the line with the open/close (petcock) on it was connected to the return line, and the other was connected to the primary filter, then the fuel pump, then the secondary filter, and then the injection pump body. QUESTION - Should the fuel tap be on this primary feed line not the return line? Remember, it was running a month ago with the lines as I found them today.

2. What kind of fuel pressure should the pump be putting out? It's really slow and hardly any pressure even though it's a recently replaced pump (doesn't look like an OEM pump).

My next steps are to install fresh fuel lines, empty the fuel tank, clean it, install fresh diesel. But as per the attached diagram, I believe the fuel feed line should have the petcock at the tank correct?

I got lost in your description. The fuel lines should be hooked up just like in the diagram you posted. If they aren't, fix them. Should suck out of the bottom of the tank, and return at the top.

J-Mech, sorry for the confusion, it made sense to me :-) I still need to know what kind of pressure the fuel pumps should be putting out.

if it has an electric lift pump it is just a low pressure pump for priming the system.
the injector pump creates the high pressure required to fire the injectors.

the lift pump should make maybe 4-10 psi or so
I'm not familiar with the D600 but at 15 degrees and not starting I would check and make sure the glow plugs are working.

I doubt it was cold enough to gel your fuel, but some of the low sulfur crap their forcing on us can do weird things at low temp. Clean the tank, replace and plumb the lines correctly, check for battery voltage at each glow plug with the solenoid on, and use good clean fuel with a winter additive to prevent gelling. Have you changed the filter lately? If their was water in a filter bowl, it could have froze blocking the fuel flow.

Thx guys for the replies. I found enough new fuel lines yesterday so i'll replace all the lines, check and clean the secondary filter, clean the fuel tank and petcock, and then fill it up with fresh diesel including an anti-gel additive. Hopefully I can get some garage time this afternoon.

Let us know if you get it running correctly.

Thx for all the help guys, she started right up and is purring away. Still got to put the fenders back on, but that's another day. The new CV driveshaft is so smooth, really nice compared to that Disconnect Clutch that was ready to blow.

Glad you're up and running again.