I was having a lot of trouble starting the truck in the mornings and sometimes couldn't get it started at all. Once it was warm (after amost wearing out the starter) it would be fine and would start right away. I figured it was a bad lift pump and replaced it ($$). Next morning- same thing. I then figured out that the solinoid on the injector pump isn't ingaging all the way up so I have to turn on key and manually pop up the solinoid until the magnet works. This way it starts right away even in the cold.
Question: Should the magnet suck it all the way up or is there some sort of linkage that is off, that pushes it up until the magnet takes it the rest of the way up?
Thanks in advance!!
Al

 

Two things to check:

• Make sure that the positive feed wire from the driver's battery to the relay has not corroded. (blue or brown)
• check the relay...swap out with a different one from the centre.

 

Something else to check is the bracket holding the solenoid on loose? By chance is the rod bent a little from accessing the fuel plate? Another thing to try is pull the solenoid and flip it over and chech for corrosion under the rubber boot.
Tom

 

When you press the pedal before starting, is there a mechanism that "sets" the solinoid? It seems that it is a long way for the magnet to engage. When I manually push it up, the magnet doesn't "suck" until at least 1/2 way up.
I will check wiring and corrosion etc. but am still wondering about linkage.
Al

 

When yo try to start your engine the starter solenoid puts power to the fuel solenoid on the "start side". This is how the plunger gets pulled up. When you let go of the key and it is in the run position then there is power to the "run" side of the solenoid. Try having someone attempt to start the truck while you are watching the plunger. Then you can check the opperation and figure it out from there.
Keep us informed
Tom