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I don't believe the fuel type has any bearing on the algae issue. (Also all diesel fuel sold today has the same sulfur content; the off road fuel only has the dye added.) The main cause of algae is not keeping a tank full and water condensates on the "dry" areas on the sides and tops of the...

That's why I use algaecide in all generators I service or rebuild. An equipment fuel tank sitting around for months/years on end is the perfect environment for the critters to grow & clog filters in short order... :(

Good job staying with the task....lots of work, but persistence will pay off! :)

Haven't come across this on the 24v pumps, but I'm also wondering if one of them has some sort of problem that's introducing air "right off the get-go". If he could disable one pump at a time or swap out with others one at a time, then he could observe whether air problem goes away....

Jerry, if you're talking about "leak-off lines" or return fuel lines, I've never run into any problems attributed to air in a return line causing air to get into the high pressure side. Not saying it can't happen, but after a few years working with CAT, Perkins, Ford, IHC, Allis Chalmers...

I'm still wondering if he ever connected the injectors outside the head to observe good or no pressure from the IP...

Gas will ignite easier than diesel, but will not provide the severe explosion that ether does--therefore much easier on the engine. Forgot to mention I spray quite a bit of WD40 or equal/cheaper into the engine prior to the gas trick. This will provide a little lubrication to the cylinders...

Maybe timing has changed....good fuel pressure & IP sending fuel to the injectors all good until the timing is altered. I agree some smoke should be showing up even with some residual fuel in the cylinders. Try this: 1. Remove air intake hose from the engine. 2. Soak an old rag in gas...

How about pulling the injectors and reconnecting to the HP lines outside the cylinder and then cranking over and observe spray pattern (if any)...maybe you have one or more clogged injector or one or more not functioning properly. Though unlikely, you could also have a compression problem...