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Ha! I'm late because I was tied up working.... ;) Anyway, I'm better with the 002/003 pumps than 802/803 but from what I recall you take the top nut off ( the one under the line nut ) and the guts are mostly accessible through the top. The clip on the bottom "unhooks" off the plunger ( spring...

This is just a guess, but when I first started working on the 802/803's I didn't realize that barb was a restrictor ( and this one was plugged ) so I stuck a drill bit in there and drilled it out, then realized I had drilled out brass and not garbage. I used a small bit, probably 1/16" and it...

The VR is easily replaced, If you can find one available, but its not serviceable in itself. Sometimes if you search around you can find reasonably priced new ones, but search by the Prestolite PN's not MEP-80X alternator. Also try Prestolite 24V alternator and Leece Neville 24V alternator. If...

Although at this point it sounds like you will soon have the piston removed, so you will know shortly if you have a bad bearing. I'm still not convinced your rings and the cylinder walls are the whole problem. If it was the grooves I would expect air leakage all the time, not just at the bottom...

Did you ever get a chance to check for a spun rod bearing? It's pretty simple now that the head is off. just put it at TDC, go a tad beyond TDC but not enough to begin pulling the piston down, then push on the piston with your hand a see if it moves a little bit. Or get it at TDC and rock the...

I'm in the same boat as DieselAddict, I used to buy and sell lots of these, but when the prices got to be more at auction than I sell them for retail, I backed out. I have the nicest of each model ( 831, 002, 003, 802 and 803 ) most with single and double digit hours, that I purchased very...

I would not be surprised at all if your alternator ( more likely the regulator mounted on the back of the alternator ) is dead. If the fuse is good and everything is hooked up correctly, my next step would be to test the alternator, then once that is verified, then proceed to the ammeter, if the...

Agreed... I have used the same tank and it worked fine. A little rerouting of the hoses, but fits into he holder perfectly, 2 long zip ties and DONE! The original tank can be repaired using Permatex's plastic tank epoxy available at pretty much every auto parts store in the same section as the...

So it sounds like you are using a different gage than the standard for an 803? Standard 802 / 803 gages need a 240-33 ohm sender.

Check with Mayi Diesel, I have bought oversized pistons from them before and I think they were in the $75 or less range or a piston with rings. They can be found on line. They have just about everything for LPW4 / DN4M .25mm is equivalent to a .010" oversize if they don't list them in mm.

It should be fine... and I am doing the exact same thing. I always add ATF and 2 stroke, but after seeing your plunger guide break twice in 12 months and reading the low sulfur diesel lubricity report, I ordered 2 qts. of OptiLube as well, and I'm just going to add it in on top of what...

Yup, exactly what I said in post #3. Wouldn't be the first time flood victims have rolled across the auction block!

I would still highly recommend checking the coolant system before you go too far. That oil definitely has water in it. Probably several quarts at least. Coolant in the oil will eventually delaminate the main and rod bearings if run too long, so hopefully it's recent. You are correct about stuck...

Definitely looks like coolant in the oil, however.... there are always other possibilities with "auction" equipment. Could have been a flood victim, you never know, assuming you never saw it in "Good" condition from what I'm hearing? Change the oil and filter, pressure test the radiator and see...

Talked to Ambac today and they were fine with still selling to previous customers, the only down side was that they have raised their price a bit to $20 on the GU8546 plunger guides.... worst part is shipping was $14 for something that could go in an envelope with a stamp on it. With that said...

Before you go and spend $90 on the Chinese solenoid.... just for the boot, poke around on ebay. I bought a 12V solenoid for my son's LPW2 tractor project for more like $30. maybe you can find a cheaper throw-away and just steal the boot off that one...

Sounds like you mean the notoriously tight fuel / water separator. Once you get it off you are in the clear as nextalcupfan said. Add a little oil to the gasket, install it firmly without cranking it down too tight and you will be good from no on! And while you're in there you should change the...

Well time for an update on John's situation. His pump arrived today and I was able to tear it down tonight. When it arrived the plunger was stuck pretty good and the throttle lever was very stiff. Opened it up and sure enough, plunger guide was split in half. Gonna see if Ambac will still sell...

Yup, that should work fine. The sender goes in the tank with the wires pointing to the right ( when looking from the back of the machine, so orient your spacer facing 90* clockwise from the wires. Wires facing East... Spacer facing Due South.

Something tells me GMG has just recently started offering that. In all the searches I have done for A3816 that has never come up!