dodgetrucker75

we have a 96 3500 w/manual trans, will start fine when cold but after warming up, and shutting down, it does not like to start very well untill it cools.... it will crank for 30 sec. or so and sometimes wont start at all unless the pedal is held down.

overflow valve checks ok, no load fuel pressure seems to be in spec. though i could not get a real acurate reading, also seems to be losing top end power and a loud "ticking" noise can be heard from the top of the fuel tank that when i feel it, it seems to be coming from the return line.

any ideas?

infidel

Your fuel pressure could be low due to plugged filters, bad lift pump or overflow valve.
It sounds like you were measuring fuel pressure without a gauge dampener or a needle valve barely cracked open inbetween the gauge and fuel system. The gauge will pulsate so wildly that you'll never get a correct reading in the short time before the gauge self destructs.

After you get your gauge set up right with engine running pinch the rubber return hose that passes behind the fuel filter with pliers. Your fuel pressure should shoot way up to 60-80 psi. If it goes high but drops below 18 psi with the hose unpinched your lift pump is ok, overflow valve is bad. If you don't get over 25 psi at 2500 rpm the pump is bad, filters plugged or supply line is kinked.

Also check that the shutdown solenoid is lifting up all the way when the engine is warm. Sometimes they will bind when gunked up and warm but not when cold. Take it apart and clean, replace boot if it's torn up.