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What would a less restrictive exhaust be? The stock dual system with twin large mufflers seems pretty free-flow to me. You really think you're going to improve mpg, by spending money on the exhaust?

No, the stock alts are Delco-Remy 27SI type 100 HD internal regulator units.

Have you determined that power goes to the IP shut off solenoid when key is turned on? Does the solenoid function and is it connected while you're trying to bleed lines Its usually disconnected when bleeding low pressure side to fuel filter.

A drip is not sufficient, it should spray onto the inner fenders. When I bleed the injectors I put a piece of cardboard on each inner fender. this allows you to see the spray pattern better and you don't have to clean it all up later. Only after you have a good spray out or the injectors, should...

There are a couple of spots on the top of dash for small speakers, the dash pad has square shaped hole perforations for them.

When my tranny went out, first I noticed a strange down-shifting issue when just cruising along. A week later, going up a hill, truck started shaking wildly. Then it would only go very slowly. Luckily I was very near my home, managed to crawl back like that. Had it towed to tranny shop. They...

When I first got the M1009, before I knew it burned oil, it ran low on oil. Probably was 1 and a half quarts..or more. It got to the point where coming to a stop downhill on a slope the low oil level light flashed. The engine never sounded any different. I'm puzzled as to how yours "sounded so...

Hole in one of the exhaust pipes or muffler? Cold start solenoid staying on?

I installed a civy tilt-steering column in mine, picked it up for $50. It has the stalk intermittent-wipe feature and the module. Best mod I've ever done, if you live somewhere where it rains, this is a must have. The motor/pump is the same. I bought a new OEM for $117, but you can take yours in...

Actually, it doesn't exactly fall completely out, but drops down into the recess and gets jammed in there. Requiring you to remove that plate to remove and re-insert. Hence the grease on the end trick which buys you some time to get it all bolted up. I've also never had to depress the plunger...

Mine have always fallen out, you'll have to check that its not broken. You should be able to bump the starter (disconnect IP power) or turn the motor over by hand, with a bar on the front pulley bolts. Once the cam lobe pushes it out a bit, pull it out and inspect it.

No, it isn't. Not even close. The AC60G is made in Germany by Beru. Their part number is GV004 / 0 100 271 106. The Bosch duraterm part number is 80034 / 0250202126.

Usually a hard start or rough initial idle with smoke out one exhaust is a sign of a bad plug. I check mine quickly with a test light. Pull plug wires, attach test light to positive battery terminal, touch probe of test light to each plug spade. If it lights they're good, if not, replace that one.

Just checked a spare I have, same numbers except I have F2 instead of G3. Bought them over 2 years ago, perhaps its a batch code?

What is the purpose of this? Its easier to get the rear most bolt started first as it has the worst access. Its the harder one to get threaded in, so do it first. Doing the front one first can lead you to spend hours trying to get the rear bolt aligned. Just thread it on a few turns..then...

Why not try the IP timing directly on the line or slightly retarded, see if it makes a difference.

Sounds like it could be starter solenoid, bendix not engaging. Batteries are fully charged. load tested? What kind of new starter is that, cheap chinese junk? Have an original direct drive 27MT rebuilt, they are dependable.

Hearing protection in a M1009? Really..its like you're talking about a Duece. Granted I have a civvy intake muffler on mine, might be a little quieter, but never seen anyone up here who wore ear protection. No, i am not deaf.

Sounds like your thermostat.

That's why my glow plug switch is a momentary push button.