Originally Posted by e300nocash

I'll pull the K40 relay and look at the solder joints under magnification. I have more time than money right now because I was recently laid off from an engineering job I held for more than a decade. I checked yesterday for the SOV click, and I heard it, but the car also started that time. I had a hard time hearing it when I was stuck in the parking lot because it was crowded with customers and there was a live band playing. Those bands sure do love their amplifiers.

I am focusing on the shut off valve more than ever. I was struggling to remove the clear line between it and the lift pump (those viton o-rings are as tight and as round as new ones). I removed the SOV electrical connection to get more access and it was wet inside. Both the male and female parts were wet with what I believe to be diesel fuel. It was not very pungent, but it felt like diesel fuel on my fingers. I rinsed both halves with electronic cleaner and let them dry. Assuming the factory doesn't put dielectric grease on the connection, I think I found a leak. It wasn't getting past the o-ring on the electrical connection, so that is why I saw no external leaks. I am thinking that the potting around the pins may have a hairline crack, and air is being sucked into the SOV at that point. I am also taking a look at all the other items posters have suggested, and I am grateful for the help. Does my theory sound plausible?