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You do not need to take fender off. If hinges are on door, take them off and line it up to old marks and bolt to body, that should get you close. Then put door on hinges. This job can be done alone, but it is easier to do adjustments with a helper.

Check wire by starter heat shield for worn insulation. Arcing can cause this and premature solenoid failure. Look at top of forum at Doghead starter relay sticky, if has not been done, do that. If you have one of the cheep import starters, you might want to carry an extra one (and tools) or...

Check all of above, I even had one where the steering box was coming unbolted from frame. Have also seen frame cracks where box mounts. That can be reenforced by a good welder. If you have some play in the steering wheel, but detect no play in drag link & tie rod ends, loose bolts or...

http://www.steelsoldiers.com/showthread.php?116463-Injector-return-lines&highlight=return+line I think it is the same stuff I use in my CUCV and Mercedes 240D. A couple sources discussed in above thread. I got some from Pelican Parts, but any place that sells 'Euro' car parts should have...

Just so you know, the main fuel pump will not come on if tank is too low, but the aux one will. Does low fuel fault light come on when switch is in run position?

Thanks for the warning. I noticed the return line on mine has been recently replaced, but it looks like they used 3 ft or so too much, it is flopping around. I was just going to shorten it, did I miss something about the routing of it? Ratch mentioned he saw signs the crossover battery...

Do you mean the aluminum cross over tube? JB weld or a good welder might fix it. They are the same as civy 6.2, so a junk yard might have one. I would take a look in differential and see if everything looks OK.

The only way I think it could get water is a leak in transmission oil cooling tube in radiator, unless you are going puddle jumping. Any sign of tranny fluid in radiator? Pump whining is probably due to fluid starvation of some sort. If you have heard it whining it may already be damaged, and...

I would be wondering what would cause the compression to deteriorate so fast. What is mileage, did you use either on it, any signs of bad head gasket, do you trust the shop? Could be legit, just saying.

Is the 0 ring and connection to the fluid uptake tube from the filter tight and in place?

Just got my 802 going, I lucked out and it did not have many problems. The sheet metal was all pretty abused, but inside it looked good. It took quite a bit of priming and some cranking to bring fuel up into injectors. The sheet metal, exhaust flap and such make a lot of the noise, sorting...

Thanks for posting that download. Just want to point out that it originally came from www.liberatedmanuals.com. The owner of that site is also a member here and should get some credit. Above site also has TM-9-6115-641-10(1), the operators manual, and a maintenance manual (641-24). I just...

I had one rebuilt for under $500 at American Diesel Service. They seemed competent and they rebuilt and sent me one right away and I sent them my core back in their box. I think the core charge was around $150 if I had not sent mine back. Truck runs fine now.

Since a lot of these units have had water in them, am wondering if you could have an ice blocked line or something.

The green wire on the IP is cold start timing advance, the other green wire connected to it is cold start idle boost solenoid. The one on the radiator is the low coolant lamp. Pretty sure they are un related. Sounds like you may have had air in fuel from sitting, just a guess.

Looks cool, I would check laws about that, which vary a lot from state to state. I almost bought a car from Fl recently, until I found the tint was too dark for LOEs in 2/3s of states, including (of coarse) mine.

Don't forget to let the folks on Smokstak know you have the 12v ones available.

I think someone has mentioned this, but wouldn't it be pretty easy to use a resistor to drop voltage?, like in a cucv or the ballast resistors for old ignition coils?

I recently replaced one. I ended up using a short flex head ratchet and a wobbly extension on one, and without extension on other, if I recall. It is a tight spot for a couple of the bolts.

Welcome from Mass.