I replaced the silver bolt with a new gold one. The spring pressure was substantially firmer in the gold bolt. I installed the new one about 1/2 of the way in and started the car... it shook like crazy (just like before) so I turned the bolt in another 1/4 of the way. Now the car wouldn't start so I backed it back off about 1/2 a turn. Still won't start. I kept doing this until the bolt was fully out... car turns over but won't catch

Please tell me I didn't damage the IP?

I didn't turn the bolt in all the way... I could still easily turn it by hand with a short wrench. The previous bolt was turned in so far that it was bottomed out. This one still had at least 1/4" of an inch sticking out.

Thanks...

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1982 240D
2001 Ford Powerstroke (SVO converted)
2005 Lotus Elise
2008 Lexus IS-F

Try turning it in all the way. Mine is in all the way and it didn't make any difference to my engine where I set it. It ran pretty much the same with it all the way in and without it completely.

Are you sure? It doesn't even start/run with the bolt completely out...

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1982 240D
2001 Ford Powerstroke (SVO converted)
2005 Lotus Elise
2008 Lexus IS-F

Yeah. I started the engine with only a thread or two in the pump. I then turned it in 1/2 turn at a time, revving it a bit with the linkage after each adjustment to reseat the rack.

It grumbled a bit each time I turned it (when I was at the last 1/4" or so of threads left) but the idle was no more rough or smooth at any point.

Ok, I need to get it started first... it won't catch and run with the bolt in any position. I was afraid I turned it in too far and damaged something internally.

I'm going to try putting the old bolt back where it was first... if it doesn't start then I know I have a problem. Any other ideas on how to "unstick" the rack?

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1982 240D
2001 Ford Powerstroke (SVO converted)
2005 Lotus Elise
2008 Lexus IS-F

Well I'm an idiot. There was nothing wrong with the IP... when I put the new bolt in I didn't realize I knocked one of the vacuum lines loose. I plugged it back in nice and secure and she fired right up (this may be my new anti-theft idea when parking in a rough area )

Still has the crazy rocking at idle though... I have the new rack damper bolt most of the way in and it doesn't seem to make much of a difference

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1982 240D
2001 Ford Powerstroke (SVO converted)
2005 Lotus Elise
2008 Lexus IS-F

Why does the engine need vacuum to start?

Ditto. If you knocked off the vacuum line from the injection pump, it would start but not shut off.