Here's where I am now after several days of working on this thing and wanting to give up on it several times.

Completed the swap of the 617 NA IP with the 617 turbo IP.

It started after several attempts but then it would die.

It had too much air in there from somewhere I guess, because after it would start I would use the hand pump and bubbles would come out of the return line which was submerged in a jar of straight diesel. It ran and idled beautifully on the straight diesel for several minutes then die.

I thought it was sucking air from the line attached to the primary filter so I hooked it up to the (50/50) tank and clamped it down and tightened down on the lines to and from the secondary filter and on the IP. Hand pumped again till all the bubbles came out the return line still in the jar. There must have been air in the injector lines because it took several more times on the starter to get it started again. Just almost got it started and the started failed.

Swapped the starter from the 617 NA on my engine stand and cranked again. It started up and ran and idled beautifully.

I got real brave and ventured out about 3 miles. I almost got it home and it died again. Fortunately, it was in walking distance from my house. I let it sit for the night then today I walked back and hand pumped it cranked it about 6 or 7 times and drove it home.

It was running and idling perfect by the time I got it home. I pulled off the return line while it was running to put it back into a jar and see it there would be air when I hand pumped. There was NO fuel coming out of the return line at all. I hand pumped while the engine is still running and just a very little fuel is flowing through return line. The engine is still running perfectly even when rpms are high and retuning to idle normally. little to no fuel retuning from the return line. I pulled the return lines off each injector and a very tiny amount is coming out in some cases none.

Does this mean bad injectors? But, the IP must not be releasing the fuel from the IP either since no fuel is coming out the return line.

What do you think????
Thanks for your comments!!!

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83 300SD
80 300D