1994.5 7.3 Direct Injection Turbo Diesel Wait To Start light blinking No Start - PowerStrokeNation : Ford Powerstroke Diesel Forum
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post #1 of 21 (permalink) Old 10-05-2018, 07:12 PM Thread Starter
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1994.5 7.3 Direct Injection Turbo Diesel Wait To Start light blinking No Start

Hello all, I'm looking for some guidance on troubleshooting my no-start problem. Truck ran fine up till now, I was just driving it a couple nights ago, started and ran no problem. Two nights ago, this issue began and now it won't run.

As the title says, the Wait To Start light is blinking. Relay #2 under the hood clicks on and off simultaneously with each blink of the Wait To Start light. Engine cranks fast and strong but doesn't start.

This is a midyear 1994 7.3 Direct Injection Turbo Diesel mated to a ZF S5-42 manual transmission, installed in a 1991 Centurion Classic C350 that originally had a factory 7.3 IDI and E4OD. I did not do the swap, but up to now it has been working fine for the four years we've had the truck. Not sure if any of that matters, I just want to be thorough.

Two new batteries only a couple months old, EverStart MAXX-65N rated at 1000CA, 850CCA. Earlier this summer I put in a new starter, new glow plug relay, new battery cables. Batteries are on a slow-charge smart battery minder while I troubleshoot this problem. I have good voltage and amps at both batteries, 12.6vdc cold. Current temps are around high of 51, overnight lows 45, midday about 48, I really don't think the cold is a significant factor but I could be wrong.

When cold, the engine will spin fast but won't start, and after a few seconds starts blowing clouds of unburnt fuel smoke. I plugged in the block heater last night, and this morning I can get it to start briefly. It surges or pulses with each flash of the Wait To Start light/relay #2 click, and then after a few surges it dies. It cranks right up each time I try while it's warm, and immediately starts surging with the blinking light and dies after a few blinks.

I know it's getting fuel and it has good voltage, this makes me think the PCM is turning on and off with each flash of the Wait To Start light. It has power at the internal power points, and as far as I can tell everything else electrical seems to be working properly. What I can't figure out is why the #2 relay is clicking on and off.

I've searched various forums and checked all the obvious things people mention. I don't see and bad fuses, and swapping the relay with another known good relay does not resolve the issue. From my research it looks like a common suggestion is it could be a bad PCM maybe? or wiring fault going to the PCM maybe?

So I could do with advice on this. Am I missing anything? What else can I check or what should I be looking for?

"Das Berserker Bus" 1991 Centurion Classic C350 4x4 4-door Bronco with 1994 T444E ZF S5-42
"Der ShortBus ('cause it's F'in' retarded!)" 1993 Bronco on shortened 1997 F350 4x4 PowerStroke ZF S5-47
"The Ranger" 1998 Ford Ranger 4x4 extended cab
"Stella the Red" 1998 Toyota Rav4x4
"Mjolnir's Cousin Biff" 1986 AM General M923
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post #2 of 21 (permalink) Old 10-05-2018, 07:15 PM
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Re: 1994.5 7.3 Direct Injection Turbo Diesel Wait To Start light blinking No Start

You're correct. Pcm is going on and off.
Try replacing that pcm relay, as well as unplug the fuel heater on the filter bowl.
Do you have a chip?

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1979 chevy c30 dually, sm465, 373's? Converted to 6.2 diesel, pump turned up and advanced a hair.(wrecked)
1994 ford F350 dually 4X4: 7.3 powerstroke, 5 speed. 6637, straight pipe into dual stacks. Cooper discoverer at/3's.
2010 Jetta TDI 40 or so mpg :flippa:
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post #3 of 21 (permalink) Old 10-05-2018, 10:05 PM Thread Starter
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Re: 1994.5 7.3 Direct Injection Turbo Diesel Wait To Start light blinking No Start

Quote:
Originally Posted by 79jasper View Post
You're correct. Pcm is going on and off.
Try replacing that pcm relay, as well as unplug the fuel heater on the filter bowl.
Do you have a chip?

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No chip. As far as I know this is a compleatly Stock engine.

If you mean replacing relay #4, I have already done that. New relay clicks on and off same as old relay.

Where is the fuel bowl heater plug? I have seen a number of references to that, but have not found it. What exactly am I looking for, and where?

"Das Berserker Bus" 1991 Centurion Classic C350 4x4 4-door Bronco with 1994 T444E ZF S5-42
"Der ShortBus ('cause it's F'in' retarded!)" 1993 Bronco on shortened 1997 F350 4x4 PowerStroke ZF S5-47
"The Ranger" 1998 Ford Ranger 4x4 extended cab
"Stella the Red" 1998 Toyota Rav4x4
"Mjolnir's Cousin Biff" 1986 AM General M923
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post #4 of 21 (permalink) Old 10-05-2018, 10:41 PM
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Re: 1994.5 7.3 Direct Injection Turbo Diesel Wait To Start light blinking No Start

On the driver side of the filter housing, should see 2 plugs about midway down the housing. It's the upper one.

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1979 chevy c30 dually, sm465, 373's? Converted to 6.2 diesel, pump turned up and advanced a hair.(wrecked)
1994 ford F350 dually 4X4: 7.3 powerstroke, 5 speed. 6637, straight pipe into dual stacks. Cooper discoverer at/3's.
2010 Jetta TDI 40 or so mpg :flippa:
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post #5 of 21 (permalink) Old 10-05-2018, 11:12 PM Thread Starter
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Re: 1994.5 7.3 Direct Injection Turbo Diesel Wait To Start light blinking No Start

Quote:
Originally Posted by 79jasper View Post
On the driver side of the filter housing, should see 2 plugs about midway down the housing. It's the upper one.

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Included are pictures I just took of the fuel bowl. The only plugs I can see are on the passenger side, low down, one to the front and one to the back. Picture 001 is a pretty good shot of it. Picture 002 is the front of the bowl, no plugs I can see. Picture 003 is the driver's side, and again, no plugs I can see.
Attached Images
File Type: jpg C350 Fuel Bowl 001.jpg (24.0 KB, 13 views)
File Type: jpg C350 Fuel Bowl 002.jpg (24.4 KB, 13 views)
File Type: jpg C350 Fuel Bowl 003.jpg (25.6 KB, 13 views)

"Das Berserker Bus" 1991 Centurion Classic C350 4x4 4-door Bronco with 1994 T444E ZF S5-42
"Der ShortBus ('cause it's F'in' retarded!)" 1993 Bronco on shortened 1997 F350 4x4 PowerStroke ZF S5-47
"The Ranger" 1998 Ford Ranger 4x4 extended cab
"Stella the Red" 1998 Toyota Rav4x4
"Mjolnir's Cousin Biff" 1986 AM General M923

Last edited by IsaLandr; 10-05-2018 at 11:13 PM. Reason: word correction
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post #6 of 21 (permalink) Old 10-05-2018, 11:26 PM Thread Starter
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Re: 1994.5 7.3 Direct Injection Turbo Diesel Wait To Start light blinking No Start

The first picture here is the fuel bowl from our 1997 7.3 PowerStroke. I see what I think are the plugs you mean on the driver's side. The second picture is The 1994.5 7.3 PowerStroke, and as you can see, they are different, the older one does not appear to have that plug on the driver's side, although the fuel bowls are very similar otherwise.

I think you can see now why I am not sure what I'm looking for or where on the 1994.5 engine.
Attached Images
File Type: jpg B350 Fuel Bowl 002.jpg (28.7 KB, 10 views)
File Type: jpg C350 Fuel Bowl 003.jpg (25.6 KB, 10 views)

"Das Berserker Bus" 1991 Centurion Classic C350 4x4 4-door Bronco with 1994 T444E ZF S5-42
"Der ShortBus ('cause it's F'in' retarded!)" 1993 Bronco on shortened 1997 F350 4x4 PowerStroke ZF S5-47
"The Ranger" 1998 Ford Ranger 4x4 extended cab
"Stella the Red" 1998 Toyota Rav4x4
"Mjolnir's Cousin Biff" 1986 AM General M923

Last edited by IsaLandr; 10-05-2018 at 11:47 PM. Reason: additional information
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post #7 of 21 (permalink) Old 10-06-2018, 04:16 AM
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Re: 1994.5 7.3 Direct Injection Turbo Diesel Wait To Start light blinking No Start

I can assure you it's there. Lol
You see the terminal sticking out below the round piece? It's the rectangular one above that.

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1979 chevy c30 dually, sm465, 373's? Converted to 6.2 diesel, pump turned up and advanced a hair.(wrecked)
1994 ford F350 dually 4X4: 7.3 powerstroke, 5 speed. 6637, straight pipe into dual stacks. Cooper discoverer at/3's.
2010 Jetta TDI 40 or so mpg :flippa:
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post #8 of 21 (permalink) Old 10-06-2018, 04:42 AM Thread Starter
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Re: 1994.5 7.3 Direct Injection Turbo Diesel Wait To Start light blinking No Start

Quote:
Originally Posted by 79jasper View Post
I can assure you it's there. Lol
You see the terminal sticking out below the round piece? It's the rectangular one above that.

Sent from my SAMSUNG-SM-G930A using Tapatalk
Wow. I can't even see that far down next to the side of the bowl. Now I know what I'm looking for, and how far down, I'll see what I can find tomorrow.

Thank you for this, you've been very helpful. I would never have found that on my own. I was always looking way too high on the bowl.

Does it just pull straight off, or is there a catch or some kind of locking mechanism? Special way or special tool to get it off? Or just pull it straight off towards the fender till it gives?

"Das Berserker Bus" 1991 Centurion Classic C350 4x4 4-door Bronco with 1994 T444E ZF S5-42
"Der ShortBus ('cause it's F'in' retarded!)" 1993 Bronco on shortened 1997 F350 4x4 PowerStroke ZF S5-47
"The Ranger" 1998 Ford Ranger 4x4 extended cab
"Stella the Red" 1998 Toyota Rav4x4
"Mjolnir's Cousin Biff" 1986 AM General M923
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post #9 of 21 (permalink) Old 10-06-2018, 04:53 AM
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Re: 1994.5 7.3 Direct Injection Turbo Diesel Wait To Start light blinking No Start

It could be stuck, but no release or anything.
A long flat screwdriver works well.
The plug below it is the water in fuel sensor.

Sent from my SAMSUNG-SM-G930A using Tapatalk

1979 chevy c30 dually, sm465, 373's? Converted to 6.2 diesel, pump turned up and advanced a hair.(wrecked)
1994 ford F350 dually 4X4: 7.3 powerstroke, 5 speed. 6637, straight pipe into dual stacks. Cooper discoverer at/3's.
2010 Jetta TDI 40 or so mpg :flippa:
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post #10 of 21 (permalink) Old 10-06-2018, 03:20 PM
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Re: 1994.5 7.3 Direct Injection Turbo Diesel Wait To Start light blinking No Start

I doubt that the fuel heater is what is causing the problem but it could. If you don't see in on the outside of the bowl you can unplug it on the inside also. It is the only wire that is on the inside of the bowl.

Check fuse #9 in the under hood box or just replace it with a known good one. #9 sends the power to the PCM. Also check the connector to the PCM to see if it is loose. It almost sounds like a bad wire going to the PCM or the ignition switch.

96 F250 XLT 4x4, 4:10 gears, 5 speed, Tymar intake and HX hose, downpipe, pyro and boost guages, coolant filter, Luc clutch
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