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Success! I didn't nail down exactly the root of the problem, but I pulled apart the rear injector and verified no junk internally and plunger moved freely. I reset the injector positions and verified rack function, fuel return flow, and re-bled the injector lines. Hit the starter and it took...

We use PEI Genesis to source Mil-Spec connectors at work. They have technical guides that should help ID your missing connectors. Just be warned, they are expensive. Solution Guides

Yes, I did that first before attempting to start the engine. There was good flow at the injectors and purge vents on the canister filter. The old filters still looked really good. Based on hrs and date written on the filters, this engine has sat a long time without being run.

A step forward, a step back. My new gasket showed up, so I got back to work today. First thing was tearing apart the pressure relief. It was definitely stuck. After removing the retainer and spring, the plunger would not come out. I flipped it over and had to tap it out with a hammer and...

Thanks Ray, I was surfing around for the best deal on those.

Removing the side cover was no issue, but the gasket got destroyed. Removing the pressure relief was easy. I love how servicable the engine is. Once open, I think I understand what might have happened. Though there was no water when I changed oil, it is clear there was at least some moisture...

Ray, you nailed it. Holy moly that's a lot of pressure!

It's been in the garage. Outside air temp has been 40°F That's an interesting thought! The oil pressure gauge doesn't work, so I'll rig up something manual. I had a little more success tonight. Through several starting attempts, the engine would run progressively longer each time. One...

The fuel system is primed and I'm getting squirts when I crack the line nuts at the injectors. I followed the TM, opening the lines at the IPs first and loosening the IP nuts, then the injectors nuts. I have not checked the fuel return to the tank yet.

I'll 2nd DieselAddict's comments. Once per week is more than you need to exercise it. I typically run mine once per month. Let it warm up for 5 minutes, then apply a load for 30 minutes to an hour. I start the load and 50% and work up to 80%, with intermittent pulls to 100% to test...

Hey all, I bought another non-running MEP-802a. It was robbed of many parts, so I've been going through it. I was told it ran and made power at one point, but engine quit starting one day. So far I've fixed the well nut, added the MOV, and dropped in some new batteries. After changing...

2x recommend load banking the unit once a month if you don't already. 70-80% of max rating usually works. With the oil gauge, double check end-to-end for loose connections, it may be a coincidence the gauge is pegging. If your really concerned, buy a new bottle of oil from a different source...

Follow on question: I have restarted this unit cold with ambient temps ranging from 35-65°F. The unit pops right off when I hit the starter, but struggles a bit to climb to 1800 rpm (60Hz). It rolls a decent amount of black smoke for a few seconds, then clears and hits 60hz. From there, it...

I remembered when I was setting the IPs with the bore scope, if the IP was rotated too far CW or the fuel rack travelled beyond its normal stop, the little fuel levers would come out of the rack slot just enough to jam the rack or worse, would come out of the slot all together, causing them to...

I "think" I figured this out. I took the front cover off the engine because the rack was getting stuck again. A little tap on the end freed it up, but it would get stuck occasionally when it returned to the off poistion. With the cover off, I reinserted the IPs again, but watched each one...

I was getting fuel to the IP. I will re-verify since I've had the IPs in and out about 8 times now. Noted about the lifter.

Okay, a little more progress made, but still not running. I pulled the 2nd IP and tested the rack. It functions properly with no IPs in place. I exercised the IPs a bit and stuck them back in. Cranking the engine over with a bit of ether got it rolling fast enough to fire. It was clear it was...

A MEP-802a makes really good, clean power and will have no issue driving an inverter/charger. Grid Power: Honda EU2000i MEP-802a For comparison, this is a 3600 rpm, brushed generator:

Okay, I pulled the forward metering pump so I could see the rack. - Pulling the run lever does not move the rack. - Pulling the run lever and cranking the engine does not move the rack. - When I pull the run lever and give the rack a nudge, it pops loose and moves back and forth with the run...

Not yet. It's 0 degrees today, so motivation is a little low. I do have a spare 802a I can swap parts from. I also need to lookup what the proper pressure is from the lift pump.