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Notice the dab of orange paint on the retaining screw? That's tamper evident paint. You're not supposed to be taking that part off the pump. Don't blame the engineers for this one. Do take the injection lines off. The engineers made it easy. They come off in pairs.

If it's jumpy there is air in the system. You'll need to run the cylinder through several full strokes to clear it out. The normal amount of noise is characteristic of the pump. Gear pumps are the noisiest, vane pumps are the quietest.

"Then I tried to hit the serations with a punch. It has flats for a wrench...

It's possibly an eductor for your air cleaner.

Never had valve recession?

You do not want to use K&N filters in dusty off-road environments. They really aren't good for on-road either. If you want the best of the best, replace the entire filter housing with a Donaldson PowerCore housing.

Tef-Gel is popular for corrosion protection in the marine industry. It's basically a grease so it won't dry or harden. You may not agree with the price tag. Dow Corning 734 is another commonly used option. It's an RTV silicone but it's flowable so you can pour it or paint it onto a surface and...

Keep in mind, if you're soaking your seal in a chemical that causes it to swell that is chemically deteriorating the seal.

Guess I just got a bunk hose. Put a new one on and power steering works fine. I got the air filter routing figured out today. A Donaldson PowerCore D080056 fits nicely between the batteries. It's meant for a 50hp industrial off-road engine but these things have so much capacity I think it will...

Diesel doesn't really have any effect on paint other than staining it. Use whatever you can get: alkyd polyurethane or epoxy. 2 part is better.

If you put a volume of fuel in and leave it running it will certainly clean it. The stacked disks units have constant flow through them. A similar size will process 200 gallons per hour. Obviously you don't need that. I'm just a centrifuge operator, not an expert. Just throwing out some things...

You can correlate fuel consumption to battery capacity reqiured. Here is a study. https://apps.dtic.mil/sti/pdfs/ADA428426.pdf Looks like they expect it to be powered by a 2KW generator. It would take four 8D batteries to run that for an hour. That is a worst case scenario.

Commercial units used stacked disks so that the debris only has to move a millimeter or so before it's "settled". The stacked disks also impart the rotation to the fluid. Without these features, effective separatation only occurs in the boundary layers of the top and bottom surfaces. I operate...

I had chipping. I wiped the areas with phosphoric acid and let sit 24 hours. I primed with one coat of Awl Grip wash and Awl Grip 545 primer rollered. I scuffed the primer to remove orange peel and then applied one cost of topcoat house paint sprayed. You don't want too many coats. As it gets...

There is a serrated edge where the cap meets the pump body. It has a small Allen screw with a plate that engages the serrations lock the cap in place. Remove this screw before trying to turn the cap. There are wrench flats on the cap near the inlet fitting. You can see them in the image I...

I looks like the end cap has to come off the pump.

Good point on end play. That can be checked without disassembling anything. Pry on the damper of flex plates. You should get an audible thunk in each direction as the crank hits the thrust bearing.

I have an assortment of Cat memorabilia on my refrigerator.

So I've only opened 3 GM engines, a 350 a 6.2 and a 6.5. The front cam bearing certainly takes a brunt of the wear on those engines I have opened. You can't really judge oil starvation from the cylinders. They're the last to be affected. I strongly suggest checking mains and rods. At least...

Inlet screen on the injection pump? Are there no other filters before it? A screen on the IP should NEVER clog.