Chevrolet Repair: 98 Chevy 3500HD hard starting hot, gm truck, loose ground


Question
I've had the above truck since new and it developed a hard starting hot problem after about 1.5 - 2 yrs old.  It's been in two different GM truck centers - replaced fuel pump 4 times, regulator 4 times, they've checked fuel pressure, everytime OK, they've been thru the fuel system completely, all wiring is OK, and both have basicly given up.  No one can come up with anything/ or figure it out.  Also, you fill both tanks up and when the gauge says 1/2 tank, it won't start at all.  Even though I, myself have pulled fuel pump and tanks have been half full.  At that time, I couldn't see anything wrong with fuel pump.  Any feedback is greatly appreciated.  Please help!

Answer
Thought 1. That is probably a 454? If so, it probably has a hot fuel handling module which is supposed to keep the pump running for about eight seconds, rather than the normal two seconds.
This is to circulate fuel, and avoid vaporlock.

Thought 2. The fuel pressure tests ok when it won't start??
If so, then there must obviously be no spark, or no injector power.
Some association with the instrument cluster comes to mind, and a loose ground is all I can think of that even remotely might affect it that way.

I am curious if the pump is still submerged, and if it is running.

I am aware of another person with a Suburban, that the engine will run if it is below a 1/8 tank of fuel, or 100 miles to empty I think, but if it is shut off at 1/8 or below, it won't start. That problem has not been solved yet, to my knowledge.

Following is a link to that discussion if you would like to follow it. I am fixitfox33 there.

http://www.chevytalk.org/threads/showflat.php?Cat=0&Number=1649346&an=0&page=2#P...

Van