Attention: TDR Forum Junkies 
To start; my truck never had any problems starting, but the fuel pressure was always low (4psi-10psi). The night before the truck decided not to start, it was really low on fuel. Went out the next morning to go fill her up and wouldn't start. I just figured I ran it low enough on fuel that there wasn't anything left. (**added note: I've searched for several hours on this forum for the next several problems, just getting that out of the way!!)
So I took my other truck to get 5 gallons worth of fuel and put that into the truck. Pushed the primer several hundred times... . nothing, still wouldn't start.
I thought ok, just need to crack the injectors and bleed the air. Couldn't get any fuel out of them. So I checked the filter: pulled the water drain, plenty of fuel there. Unscrewed the bleed valve on top of the filter, plenty of fuel on the first primer push. So I have fuel from the tank to the filter.
Since I have problems with fuel pressure I took the overflow valve off to examine it and see if I could get fuel out of the overflow hole. The spring measured 7/16 (I figured it compacted) so I stretched it out to 1/2 inch. I will order a new one soon. Pushed the primer for several minutes and couldn't get any fuel to come out of the overflow hole. I wasn't sure if it was possible to get fuel out there with the banjo removed so I put it back in. Moved on to the battery, solenoid, relay and fusible link on the battery:
I took the battery connections apart, cleaned them and replace the drivers side positive terminal connection. During this time I notice that I didn't have the blue fusible wire that I hear so much about. I think its been replace with a red wire (before I took ownership of the vehicle). So Im not really sure which of the two red wires on the positive terminal are supposed to be the red one.
Moved to the fuel shut-off solenoid. I noticed that with the key on, the solenoid never moved up. NOW Im making some progress. Manually lifted the solenoid up and it stayed, so I know Im not getting the juice to lift it and the ignition switch is keeping it up. Just to make sure it wasn't the solenoid binding. I removed it and examined it. The shaft moved very freely and the linkage it connects to does also. With the solenoid removed I turned the key to run, still didn't move. I manually move the shaft up, it stayed, then popped out when I turned the key off. The solenoid has been ruled out of the problem.
I put it back together and tried starting the truck by manually lifting the solenoid up. By now the battery and starter are getting tired. I put the jumper cables on and tried again. After several tries the truck began to sputter. Cracked the first three injectors and primed some more. Just a light sputter and no fuel from the injectors.
This is where Im at now. Not really sure whats going on and why I cant get fuel from the injector lines. I haven't replaced the fuel relay yet because I ruled out the solenoid and manually lifted it up so I should still be able to start the truck. But now Im running out of ideas. A couple of times it sounds close but sounding close without fuel from the crack injector lines is still a long way from running.
ANY IDEAS????
So I took my other truck to get 5 gallons worth of fuel and put that into the truck. Pushed the primer several hundred times... . nothing, still wouldn't start.
I thought ok, just need to crack the injectors and bleed the air. Couldn't get any fuel out of them. So I checked the filter: pulled the water drain, plenty of fuel there. Unscrewed the bleed valve on top of the filter, plenty of fuel on the first primer push. So I have fuel from the tank to the filter.
Since I have problems with fuel pressure I took the overflow valve off to examine it and see if I could get fuel out of the overflow hole. The spring measured 7/16 (I figured it compacted) so I stretched it out to 1/2 inch. I will order a new one soon. Pushed the primer for several minutes and couldn't get any fuel to come out of the overflow hole. I wasn't sure if it was possible to get fuel out there with the banjo removed so I put it back in. Moved on to the battery, solenoid, relay and fusible link on the battery:
I took the battery connections apart, cleaned them and replace the drivers side positive terminal connection. During this time I notice that I didn't have the blue fusible wire that I hear so much about. I think its been replace with a red wire (before I took ownership of the vehicle). So Im not really sure which of the two red wires on the positive terminal are supposed to be the red one.
Moved to the fuel shut-off solenoid. I noticed that with the key on, the solenoid never moved up. NOW Im making some progress. Manually lifted the solenoid up and it stayed, so I know Im not getting the juice to lift it and the ignition switch is keeping it up. Just to make sure it wasn't the solenoid binding. I removed it and examined it. The shaft moved very freely and the linkage it connects to does also. With the solenoid removed I turned the key to run, still didn't move. I manually move the shaft up, it stayed, then popped out when I turned the key off. The solenoid has been ruled out of the problem.
I put it back together and tried starting the truck by manually lifting the solenoid up. By now the battery and starter are getting tired. I put the jumper cables on and tried again. After several tries the truck began to sputter. Cracked the first three injectors and primed some more. Just a light sputter and no fuel from the injectors.
This is where Im at now. Not really sure whats going on and why I cant get fuel from the injector lines. I haven't replaced the fuel relay yet because I ruled out the solenoid and manually lifted it up so I should still be able to start the truck. But now Im running out of ideas. A couple of times it sounds close but sounding close without fuel from the crack injector lines is still a long way from running.
ANY IDEAS????
