Starting problems

[82silverado]

Hello there Diesel Comrades
I am slowly making progress in the very basics of mechanical works. Trial and error, ya know?

Well, I've got a 1982 Silverado 6.2l diesel with aftermarket turbo and since I live in Michigan and it's winter I was having some trouble starting vehicle. (Side note: I've yet to locate block heater plug-in, is it found beneath or on top of engine?)
Put in 2 new batteries with 1000 cranking amps apiece. Replaced 4 of the 8 easier to reach driver's side glow plugs and due to excessive white smoke I also thought I would change the fuel filter.
When I replaced the fuel filter I did not realize at the time I was suppose to fill it back up with fuel. Did not mention it on the box nor do I recall it mentioned in the 6.2l troubleshooting guide...so I go and turn the engine over and it starts right up, runs for a few minutes and stalls. I figure it ran out of fuel and I opened the filter drain to purge air and try starting again. Cranks over and nothing.

Now, I tried it again and no cranking...oops, what happened?
I filled fuel filter with fuel. Mechanic down the street send it could be the fusible link.
If this is so...What size wire is recommended and since I am new to this (I do have haynes diesel manual for looking up stuff) where exactly is this fusible link? Visibly connected to the starter? I am hoping that is the problem and not a new starter? I honestly was not cranking and cranking, but may be there was extra power sent to the starter via new batteries?

I am glad for this site as I will be inquiring more to try and get a grasp on what makes this diesel tick. I genuinely want to learn and even wonder if there is a good diesel school somewhere people recommend.

Thank you for your assistance in advance!

[john8662]

So no crank at all now? Do you have power in the cab? if you have power in the cab its most likely not the fusable link, but still could be one of them. There will be either two or three wires that tie down at the starter that come off the MAIN power lug. One of the wires will obviously be the start wire (S terminal on the solenoid on the starter) and the other(s) are power to the cab, and those are fusable. First off, if no power in the cab, check the junction on the firewall nearest to the drivers side. You'll see a #10 gauge red wire with a terminal, remember this is behind the engine on the firewall (redily visable). Check for power at this point, if good, It might just be your starter.

Once you get the no cranking situation figured out, you'll then need to get the fuel system primed and get the engine running again. If you've air locked the system, the best way to prime it again is to loosen at least 4 injection lines on the injectors. Just loosen the lines, don't take them off. Then crank over the engine in 10 second intervals until you get diesel fuel weeping out the loose injectors. It's best if you can do them all, but since you have a turbo, its going to be a little bit harder on the passengers side. Once you get them weeping fuel well, you can tighten them back up, and you should be able to get the engine running within a few more cranks.

You mentioned you were changing glow plugs and you didn't change the passengers side bank. What aftermarket turbo do you have on your truck? There were three (two popular ones though) the Banks and ATS were common and at a distant third a rayjay kit. Anyways, if you have the ATS, two of the plugs are near impossible to change, if you have the Banks you can replace the plugs a little easer.

[82silverado]

Hi thanks for the quick response
I am not certain which type of turbo it is as it was already on the truck when I bought it. The guy I bought it from didn't specify a brand and I did not think to ask. May be a photo would be of help.
I do have power in the cab. One detail I remembered this morning was that after the new glow plugs were put in and filter was changed and after it had stalled out and I was cranking it over again, the engine turned over faster. Is that a result of the glow plugs or could it be the starter sped up and died?
If its not the fusible link then is it most likely the starter. I admit that it has been a tough winter for it because I haven't plugged it in and it had old plugs, batteries, etc...
I wonder if it is just best to remove it and take it in to be checked and/or replace?

Thanks

[john8662]

If if doubt, pull the starter and have it tested, they're not light but not too bad of a job! Keep us posted.

[dieselbegreat]

Re the block heater: on mine, I think I recall it is in the center freeze plug on the driver side of the block, with a flat power cord that runs along the oil pan to the front and up to a wall plug around the battery/washer reservoir area. The wall plug has a little plastic cover on it to keep it clean.

[82silverado]

Hi Folks
A little wore out from wrestling with the truck all day in the snow. Got the new starter installed and it turns the engine over better than ever. Now I am back to original problem of what I think is an "air lock". Turns over great but no firing up. I purged 6 of 8 fuel lines where they meet the injectors, put new fuel in the fuel filter, cranked starter and gave couple minute pauses in between so I don't do the new one in. I will review air lock solutions as mentioned and if any one else thinks they might know that would be great. Gotta get this beast running soon...

[82silverado]

P.S.
A couple times it did fire up for a second, but it would take hold, if that helps the diagnosis
Thanks

[boogie95]

Does it have the mechanical lift pump? if it does i've seen those cause problems with trying to reprime.

[boogie95]

Lift pump gets really weak and you may also notice extented cranking before starting.

[82silverado]

Hello!
Good news I got the old 82 running today!
Took awhile of cranking and letting her rest. I tried the wd-40 as mentioned in the website to no avail. I used a spritz of starter fluid after the glow plugs were already cycling to finally get some action and it worked.
I am sure glad to be driving again and I will never chang the fuel filter again without priming it with fuel first.
Thank you Diesel People for your assistance with this obstacle, I appreciate it.
Onto new areas that need addressing...