91 FJ80 starting issues ...

[jeffryscott]

I've had my 91 FJ80 for ~3months and I have occasional problems getting it started. As far as I can determine, I am thinking either a bad ground somewhere, or a bad ignition switch.

Symptoms are when I turn the key, nothing. All accessories come on, everything works as it should but the starter solenoid won't click. I can turn the ignition off and try again and sometimes it catches, sometimes it doesn't. I find juggling the ignition (slightly pulling the key in and out) sometimes works as well. I do not have factory or dealer cut keys and I do question the quality of my current keys ...

That said, it always eventually starts, but I worry about the day when it won't.

I am looking for ideas of where to start to further troubleshoot this, and/or solutions if others have had a similar issue.

Thanks,

Jeff

 

[ashooter]

Starter contacts might need to be replaced? My symptoms were different, but that is a repair that seems to be pretty universally required in the 80 as it ages.

If you haven't already done it, I'd suggest posting your query at ih8mud.com in the 80's tech section. Pretty much every problem a Cruiser has ever had has been diagnosed and fixed by at least a few "mud" members. "mud" is an AWESOME reference for stuff like this.

 

[1911]

If it only does it when the engine is fully-warm, it's the fuel injection relay in the main fuse box on the driver's side front fender in the engine compartment. A well-known failing of the 3FE in early 80-series. You can either carry a spare and swap them out (once cooled they will work fine, until they get too hot again) or replace the relay with a heavier-duty generic 12-volt relay (that's what I did on mine, and never had the problem ever again).

 

[mmuthart]

If it only does it when the engine is fully-warm, it's the fuel injection relay in the main fuse box on the driver's side front fender in the engine compartment. A well-known failing of the 3FE in early 80-series. You can either carry a spare and swap them out (once cooled they will work fine, until they get too hot again) or replace the relay with a heavier-duty generic 12-volt relay (that's what I did on mine, and never had the problem ever again).

If EFI Relay is the problem, the engine will crank just fine but will not start due to lack of spark and fuel.

 

[ashooter]

If EFI Relay is the problem, the engine will crank just fine but will not start due to lack of spark and fuel.

Something else that can cause it to crank but not fire when the engine's hot is the "fuel pulsation damper". I had this "hard start when hot" problem and a new EFI Relay didn't fix it. Replaced the pulsation damper and haven't had the problem since.

I also replaced the "fuel pressure regulator" a short time later, just because it was 19 years old, but I don't think that had anything to do with the startup problem.