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The pink wire allows fuel to be injected when 12 volts is applied. When 12 volts is removed, the solenoid forces the metering valve full clockwise. This valve is probably stuck in the closed position. Make sure the energized to run engine stop solenoid functions correctly, you mentioned you...

Per the 42 page technical paper on the glow plug system, the controller opens the solenoid connection at 16.2 volts measured at the solenoid. Probably because each plug draws over 8 amps and through the 18 gauge wire to each plug, there is a significant voltage drop.

If the glow plug controller fails in a certain way or the glow plug solenoid sticks closed, the glow plugs can cascade fail as voltage to plugs increases when one or more plugs fail. I had the solenoid fail three years ago, when I replaced it, all three orange wires were connected to the output...

Completely normal, resistors only drop voltage inversely proportional to current. If you are getting 24 volts to the glow plugs, it means no current and the glow plugs are failed open. The firewall resistors have the same resistance as the combined resistance of all 8 glow plugs, this divides...

If all eight glow plugs are burned out, you will measure 24 volts at the glow plugs when energized with the stock CUCV system.

If you have fuel to the injection pump (IP) but no fuel at the injectors, the problem is internal to the pump. The fault most probable would be a stuck metering valve. This valve must rotate freely at all positions as idle speed is governed by a very weak spring which opens the valve, opposing...

I've been reading up on these vehicles and injection pumps as I can't do much other work. And TV stinks, not to mention the current state of affairs. The CUCV manuals are public domain. I've found the pump specs on line too..part of my turbo upgrade. Found a DB2829 calibration for 250 Hp 😉.

The 4521 is a 4520 with low viscosity fuel upgrades. The transfer pump blades and liner are replaced in order to use JP8 that has viscosity of 1.2 Centi Stokes, abbreviated 1.2 cStk in literature. Calibration is identical.

There are two large orange and one thin orange wires, all three go to the glow plug solenoid output. One fat wire for each bank of 4 and the thin wire goes to the glow plug controller under the dash. I can post pictures if needed.

Oh, double up on protection for your eyes when drilling starter bolts. I keep a set of magnets to capture the mess at the drill. Cool LED light from multiple angles helps greatly

Large orange are glow plug outputs, should be spliced to 4 green on each bank and these go to glow plugs. Test with multimeter. Pink is power to injection pump energized to run solenoid. Should be a tan connector on the end.

Very good intro, best of luck with the starter bolt. Remember the bracket on the non drive side, this supports the weight and prevents broken bolts. I usually start at 3/16" and have a few cobalt HSS bits for that. Then a sharp 1/4" left hand will grab easily.

Very good news. The original pump was a DB2829-4267, this was superseded by DB2829-4520. From the broken screw on the cover, it appears someone tried a field fix. Make sure to keep it clean, see if the metering valve operates freely before buttoning it back together. The cover gasket...

Thanks for the tip..great price. I used to have reservations on aluminum as I didn't know it can be soldered. I now have a good quantity of SnZn alloy rods plus have used them for such repairs.

Good deal. Easy to test the IP cover solenoids when off the pump. You can get the sealing kit from Badger Diesel, they sell through Amazon too. If the current pump body is indeed a 2829-4520, it won't have the flex ring issue of the 1984-1985 pumps. There is a MWO data plate under the...

Ouch. Not an easy screw to remove due to size. I've done it once. Be sure to cover the pump with multiple layers of tape to keep the innards clean. Before covering the pump, check the governor and metering valve as mentioned, look over the video I posted for locating the metering valve...

Doghead modification is for starter only. The glow plug system uses a pair of ballast resistors on the center firewall to divide voltage to 12 volts for the 12 volt glow plugs.

No pressurized oil goes through the head gasket. Oil from the pump goes through the oil cooler in the right radiator tank. The oil returns to the filter, then it enters the rear main bearing web and from there splits off to each lifter bank. Oil for valves rises to the rockers through the...

Yes, that is the main engine ground. Mostly for glow plugs as they draw over 100 amps on first start.

Glycol brake fluid should not be reused as it absorbs water. Don't pitch it, use it again to remove paint from hardware or other small items. Much slower than aircraft stripper but a bit nicer to your health. Zip lock bags make excellent containers for parts being stripped. Wrap them in...