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It turns out it was a couple of different issues. I don't know what caused what, but the OS in the "rebuilt" IP from Heath was bad and we had a section of burned wires in the wiring harness (buried in the harness). I have no idea what caused the burnt wiring. There were no blown fuses and it was...

Man, what a long couple of days. I won't leave you guys hanging, but I'm way too tired tonight to tell the story. We don't have it running yet, but I'm hopeful that tomorrow we will. Thanks again for all the help and recommendations. I'll report back asap.

I apologize for the radio silence. I will explain all that has gone on later, but I have a question...or two. 1) Is it possible to jump a tooth on the drive gear during the installation of a new pump? I don't mean turning the engine over with the pump removed. What I mean is, with all of the...

Check, check, and double check. Injector lines are installed correctly. Wiring and connectors look great. Grounds were a little iffy, but I cleaned those up. No change in the way it runs. Same MO. Runs like garbage with the OS connected and smooths out to normal with the OS disconnected...

Ah! Excellent information. I'm happy to pull it apart to see. One last question before I do that though. My father in law said that he thought a couple of the intake bolts go into the water jacket(s). Is this true or is he mistaken? I couldn't find a definitive answer in my super quick search...

I'm obviously not familiar with this motor, and I'm definitely not doubting you. I'm happy to do whatever work I need to in order to get this figured out, but can the engine still run extremely smooth with the injector lines crossed? The reason I ask is that we have conditions where the engine...

The motor should die when the OS connector is pulled, even with the CPS connected?

Thank you! I forgot to mention that I did set the IP timing correctly, but it doesn't make any difference in the crazy shakiness of the motor.

Okay, I first want to apologize for any conflicting information I may have posted about what works and what doesn't. For example, I was not aware that the engine would have to be cranked for so long to get it to start with either the OS or CPS disconnected. I'm normally really good about keeping...

Yes, the first thing I did when I got here was to put a new CPS in it.

Okay, I didn’t realize it took that much cranking, but it tried it again just now it finally fired off on just the OS. When it first started, it ran just like normal, nice and smooth. However, after 15-20 seconds it started to run rough again, jumping around in the engine bay just as before...

Yeah, I completely agree. I'm just trying to do my best with what I've been handed. I was not in a position to come up last summer to help when this first occurred, but I can tell you that I would have done things differently, that's for sure. The thing is, these guys who worked on the truck...

Okay, we got to talking at dinner last night and a bit more information came out about this situation. My father in law is 80 and his memory is good, but not 100%. That, and I'm not sure that he felt that some of the information I learned last night was all that important, but I think it is...

Yes, there is the APP 2 and APP3 to look at. I will post that asap. I completely forgot to check the RPM signal. I will do that tomorrow morning and report back. Thanks for the info in your other post as well. I do know where the optical sensor is, but I didn't know about that filter. I will...

Okay, there's no way I would be able to sleep tonight if I didn't get out there and check into these suggestions. We've been playing with this thing all day, so it may account for slightly low voltage, but APP 1 0.65 volts at rest, 3.75 volts at full pedal. There do not appear to be any...

Doug, thanks so much for the reply. The weather turned here so we called it a day for now. We will hit it again tomorrow and I will report back asap.

I just came in from bleeding it three more times and there has been zero change. The thing is still trying to jump out of its motor mounts and the APP is causing the strange RPM-related behavior. We can't find a low pressure fuel gauge of any kind, so Napa is having one overnighted. I'm kind...

Nope, there are no roads into Nome. Thank you though. I will hunt down a pressure gauge.

Yes, we did this a few times. In fact, I just went out and checked it again and the line is 100% bubble free. So, does the fact that the line is completely bubble free definitely rule out the lift pump (and associated bits) as a culprit or should we check the pressure anyway? We don't have a...