Start, Stall then Hard Start - Fixed

I've been chasing this problem since I bought my M1009. When I park, nose up in my inclined drive way and it sits for more than a few hours, it starts then stalls. After that it has a long crank time, often requiring me to hold the pedal on the floor. It runs rough for a few seconds then is fine after that.

I've read countless threads with others having similar problems with lots of good advise. A referenced TSB discussed the fuel pump and check valve in the injection pump.

My fuel pump had some staining near the vent hole so it got replaced. Same problem. I parked it and crimped off the return hose, thereby eliminating the injection pump check valve. Same problem.

Several threads discussed the fuel pressure sensor in the fuel filter housing so I went there next. Pulled the housing off the truck and popped out the sensor and found this.



The o-ring had cracks in it.

At this point several solutions have been pointed out.

New o-ring
Spin on filter mod
Bolt stuck in the feed hole
Freeze plug pressed in the sensor hole

I chose the bolt method.

I've even found references to the bolt method being in one of the TM's but I could not find it or any pictures of how it was done.

I backed up twenty and punted.

My original plan was to tap the feed hole 6x1.0mm and install a short bolt with a copper crush washer. Two problems with that. There is not a flat surface for the washer to seal against and the tap would only go in part way before stopping against a steel tube.



This actually works to our advantage. The starting tap is tapered at the tip therefore the hole is now tapered. I put a little thread sealant in a short 6mm bolt and tightened her down. The tapered hole made for a very tight seal.



Let thing dry for a while and reinstalled.

First thing this morning SUCCESS!

I hope that this can help others in the future.

Here is the refenced thread discussing the use of a freeze plug to effect this repair.

http://www.steelsoldiers.com/cucv/42986-fuel-filter-base-fix.html

Here is the referenced thread discussing the fuel pressure sensor and o-ring.

http://www.steelsoldiers.com/cucv/66879-hard-starting-cucvs.html

I had this same issue with fuel returning to the tank when parked uphill. It seems my problem was a break in the fuel line from fuel pump to IP. Replaced it and it is fixed.

Q: If the O-Ring is leaking after all these years, can't a simple o-ring replacement fix this for a few more years at a time? AND say, keep an envelope of them in the Glove box?

Any of the aforementioned repairs would be effective. I just chose the one I could do with what I had on hand. Cost = Free