I started by diagnosing the no start issue. It turned out to be a bad IPR (injection pressure regulator) and a bad ICP(Injection Control Pressure switch). Its also got oil leaks from the PS valve cover gasket, drips from front and rear main seals, and needs oil cooler o-rings badly. It also had a fuel bowl leak. The good news is that I tested for blow by and it has none. However, it needs a lot of work now that its running. After the first drive in it, it was apparent that the injector o-rings were trashed. So, I pulled the injectors yesterday. That also revealed a fried DS front uncover harness. So, that also led to the no start and cold start issues as there is no way that those glow plugs were working. When cold the truck idles extremely rough too, which leads me to believe that the two injectors on that side aren't even working. Anyway, the injectors themselves seem okay, but regardless, I am shipping them to Jim at Rosewood Diesel for a stage 1 overhaul/upgrade.
This is what 5 of the 8 injector o-rings looked like.
Jim will upgrade them from 90cc injectors to 160cc injectors. I'll be installing a Diamond Eye exhaust, new single mass clutch, new tuner, 6637 filter, and I already installed a brand new radiator into it. I also need to rebuild the clutch linkage, and diagnose a bad ABS sensor somewhere.
The other issue with this truck is that I will have to do a lot of electrical gremlin chasing. The wipers will stay on when you hit the windshield washer switch, and the running lights stay on when you turn the headlights off.
Oh, and I've already fixed a broken DS interior door handle and rewired in a complete DS window switch.
One bright spot is that the A/C actually works.
Once I get all of the fixes and gremlins worked out of this truck, its getting stripped & painted. Running boards are going away, as is the eye brow and the "roll-a-long" handles on the doors.
This truck is at least straight and has potential. And, even with everything I am doing to it, it will be a cheap, reliable, stable hauler when I'm done.