Hi, I'm still having fun with my starter. I put on a
factory-rebuilt unit and now I'm fairly sure I have
the wonderful hot start problem. My previous starter
had the bushings going out and required a little
persuasion with a hammer to start, but after a few
taps it would start perfectly in any condition. That
starter had a brand new solenoid, but they didn't
bother to work on anything inside the case, and it
turns out the bushings were just about gone. The new
starter just randomly won't start, perhaps a bit more
frequently when it is very hot. Wait for 5-60 minutes
of cooling and it fires right up. I'm thinking the
solenoid in starter #1 was newer/beefier than the one
in the starter currently installed. I thought about
just replacing the starter cable, but Bentley suggests
removing the fuel tank to do this, and I'm wondering
if this is truly necessary, but it does seem easier to
just install the relay.

 I went to my local auto electric shop and when he
called his Bosch distributor, they'd never heard of a
hot start relay kit. The parts man said he could
remember a relay kit to fix a hot vapor lock problem
on VW cars, but nothing for a van. So I called another
parts outlet in Kalamazoo and they said they have
plenty in the warehouse, but this is 180 miles away.
It is on my way out to Colorado, where I'm heading
this weekend (Red Rocks), so I need to pick up this
kit and then install it in some parking lot somewhere.
My questions of the day are

how much wire will I need?

how long do you think this will take to complete?

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