Archived Replaced fuel shutoff solenoid - now engine won't start

[Diesel Fever]

Hey guys,



Earlier this week while driving my truck I noticed that every bump I would hit the truck would suddenly shut down, like fuel being cut off. I checked around the fuel shut down solenoid and noticed the boot was completely torn and everything was moving around inside and it was not staying in the up position well. I ordered a new one from Geno's Garage, aswell as a new relay for the solenoid. After installing both, I tried starting the truck but it won't turn over. Just keeps cranking. In the instructions it stated that the solenoid didn't need to be adjusted and was already at the factory spec. The only thing I noticed that was differenct was the relay, I didn't try the old one yet, but they did look different in size, and mounted different, but fit the same. I'm not sure what to do now. The truck was running fine before the r&r began; with the exception of shuttin down over bumps in the road. I can't really think of anything else and seeking for help, for I am at a loss. I know every nut and bolt is on right and tight ( I took my time over 2 days ). Please if you guys have any idea what might be the problem I'd appreciate any advice you have. Thanks a million, take care.



Best Regards,

Matt

 

[KSams]

What if you have someone hold the plunger up on the soleniod while you try to start it. If it starts then then its prob a relay issue. Just a guess. Hope it helps

 

[Missouri Mule]

Did you hook up the connector?

Now on a more serious side, try turning ignition to the run position and push the solenoid up. It should lock in position if it does start truck.



If truck starts turn off and start looking at electrical stuff such the solenoid relay/wires/connectors.



If truck doesn't start or doesn't run right go back over the mechanical part of the job.

 

[Diesel Fever]

Thank you for the replies guys.



KSams - Thank you for the tip, but the solenoid manages to lock in the up position when I turn the key, so I guess the relay checks out.



Missouri Mule - Thank you for that tip, the solenoid did stay up. I guess the distance spec. of the solenoid itself might be off, and that it just isn't going up "enough" I am not sure though. The truck still only cranked. I'll start the tear down tomorrow and see.



Anyone know what the spec. is for the gap between the bottom of the plunger/adjustment nut and the very bottom of the solenoid where the shutoff lever connects? For some reason 3. 13" or so come to mind, but I'm not 100% if that is true or not. Thanks for all the help, I hope that's all it is and nothing more.



Best Regards,

Matt

 

[Missouri Mule]

Wade the fuel shut off solenoid relay only deals with pull up coil it is activated by the starter relay which activated by the start position on the ignition switch.



The run postion on the ignition switch deals with the hold up coil, it doesn't take much power to hold the rod up.



So if the rod isn't being pulled up when you turn the key to start you have problems with relay/wires.



By the way as you know the hold up coil is doing its job.

 

[Diesel Fever]

Well today I checked out all the wires and at the battery aswell. The rod is being pulled up when I turn the key to start, but the engine cranks and won't turn over. I guess that leaves whatever mechanical problems there could be with the setup. Everything seemed to bolt right inplace as the old one though. Any ideas? Thanks in advance.



Best Regards,

Matt

 

[kenny61]

What part of NJ are you in?

 

[Skydiver]

Wayde, After looking into my crystal ball I think you have a fuel line sucking air.

Do you smell any diesel?

I don't remember reading about a bad shut off solenoid and hitting a bump causing engine shutdown. I don't read every post either.

Do you own a VOM (Volt/ohm meter)?

 

[Diesel Fever]

No, no odor of diesel. I ran several searches on here on hard bumps causing shut down and just about all of them singled out the solenoid. Mine was in bad shape anyway and needed a replacement. I don't own a DMM, but I'm going to try and borrow one from work and won't be able to use it till I get home tomorrow night. I'm going to try and use my cheap needle VOM later on and check some of the wires atleast. Thanks for tips though.



Best Regards,

Matt

 

[kenny61]

PM sent. Must add more than ten chaacters

 

[kenny61]

We troubleshhoted thid down ti the solenoid is not opening up enough. disconnect and manual lift the truck started. . Opinions... .

 

[Diesel Fever]

Problem has been solved. It was the solenoid itself, the gap between the bottom of the plunger and where the shut-off lever connects into was out of spec. I shortened a good few turns and the solenoid now is opening up (moving up) enough and truck is starting up as it should. Thank you to all the members who helped out, and thank you Kenny61 for phone call procedure. Thanks again to everyone, gotta love the TDR, take care.



Best Regards,

Matt

 

[kenny61]

Glad I could help. Don't lose the number...

 

[GAmes]

Wayde,



Did you keep the old parts by chance? I need a plunger and the rod that attaches to it. Mine have pulled apart and I have then wired together. It's working, but I'm not sure for how long. thanks.



Gary

 

[Diesel Fever]

Gary,



Unfortunately, that's exactly what happened to mine. The plunger was torn in pieces, however I think the rod was okay, just rusty and still holdin' the shutoff lever :-laf. I think I have it somewhere on my toolbox. If you'd like, I could snap a pic of it and e-mail to you tomorrow or so to show you the condition. I also believe I still have all the pieces too. Take care.



Best Regards,

Matt

 

[GAmes]

Thanks Matt. I'm RVing back from Alaska, this is the first wifi I've had a chance to log onto. The rod I have is OK. I'm looking for an intact assembly. Maybe from someone who switched to a cable? I guess if it breaks again I'll replace the temp fix safety wire. It's lasted over 5000 miles so far. :-laf

 

[HBarlow]

Wayde,

Did you keep the old parts by chance? I need a plunger and the rod that attaches to it. Mine have pulled apart and I have then wired together. It's working, but I'm not sure for how long. thanks.

Gary

Hey Gary, how's the Alaska trip going? Where are you? Tess was in Alaska last week and already back home.

 

[GAmes]

Sending an e-mail Harvey.