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Re: cold starting woes
Hmm. I like the idea of fuel lines from a cost standpoint but as I noted the fuel tank is beyond inaccessible on this boat. If the pickup tube is rigid I think I'd be hard pressed to even remove it from the tank. The tank is rarely below half, newer than 10 years old, and often full at the dock as we tend to fill it up on our way in so as to avoid having to do so when we're ready to head out. So, I don't think it's in the tank. In fact, my fingers are crossed. I did not replace the fuel line between the tank and the fuel/water separator when I did the rest of the lines and there's also an ancient in-line fuel shutoff valve, that will be my next job. It will be simple to do. It would be great if 6' of new fuel line was all I needed. Next time I'm at the boat I will close the in-line fuel valve on the line from the tank, pull the feed line off the Racor and see if any fuel leaks out. Should be pretty obvious if it's empty.
What makes you think it's not the lift pump?
I'm having a hard time conceptualizing what would be going on if I had a leak on the low-pressure side upstream of (before) my lift pump. Fuel runs from the tank to a Racor filter/water separator mounted at about the same height as the middle of the tank. Then it's downhill to the lift pump which is mounted at the bottom of the engine, uphill again to the secondary filter, downhill to the injector pump, uphill to the injectors. If I had a leak either in the tank or on the feed line between tank and Racor, then that line would drain back into the tank. There would still be fuel in the Racor, and in all the rest of the lines. The lift pump would still have fuel in it (it's the lowest component in the fuel system) and access to all the fuel in the Racor. I'm not smelling any diesel in my bilge, so if there's a leak it's gotta be high up, at the tank outlet fitting or either side of my inline valve... anyplace else and I'd get diesel leaking out rather than air leaking in... right?
Any my last question: why is the engine unable to start with the fuel remaining in the secondary fuel filter and injector pump not to mention the Racor, lift pump and fuel lines? Based on the amount of mess that occurs replacing the secondary fuel filter there's at least a minute or two of fuel in there, at least a cup and probably a couple of cups in the Racor... that's why I suspected the pump.
Last edited by David Spear; 04-19-2016 at 02:56 PM.