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Old 07-04-2019, 06:19 PM
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Diseasel300 Diseasel300 is offline
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1: Some people add an electric pump to help with a weak mechanical lift pump, or to help prime the system after a filter change. I'm in the camp that thinks its entirely unnecessary. If your mechanical lift pump works then it renders the electric pump redundant. It may be a band-aid for a failed hand primer pump, if it's the type with the white or screw down handle, it needs to be replaced with the modern Bosch type replacement, the old ones tend to leak and prevent priming or cause excessive air ingress. The electric pump may also be a band-aid for a weak spring in the overflow pressure valve on the backside of the injection pump.

2: Look for a part number stamped on that "swollen" hose. If one is present, it means it's the "cigar hose" and it's supposed to be swollen. The idea is to damp pulsations in the fuel lines, it's anybody's guess if it does anything noticeable. If you're working on the return side of the fuel system, you don't need to do any sort of priming. If you're working on the suction side or delivery side of the fuel system, you should pump the primer handle until you hear the overflow valve on the injection pump squeal.

3: The line from the manifold should come into the bottom of the overboost valve and the line going to the ALDA on the injection pump should be connected to the middle port on the overboost valve. The valve should be normally open in this configuration, you should be able to blow through it. The valve "switches over" the ALDA line at the middle port to the top port (atmospheric pressure) during an "overboost" condition. The banjo bolt on the manifold often soots up as does the overboost valve. You haven't mentioned if the turbo turns freely or not.

You should consider getting a bypass pipe for the trap oxidizer. It's likely full of soot by this point and killing your power. A forum member here (I think Rollguy) sells a bypass pipe for the '85 California models.

Diesels are deceptively simple, there's a lot more nuance to them than they appear. If you're an avid tinkerer, you'll quickly learn their moods and what's what, but that's the fun of it!
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