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Old 04-16-2012, 08:35 AM
v8volvo v8volvo is offline
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Join Date: Jun 2009
Location: Montana, USA
Vehicle: '86 745, '83 764
Posts: 1,625
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Hmmm...

It sounds like you may have an air lock in the injection pump or some kind of return flow blockage. You'll probably want to go through and fully bleed the system as a starting point, and move forward from there. Did you replace the fuel filter? If so, how did the old fuel look that came out of the one you took off? Any obvious crud in there?

Here is what I would do. Assuming you have a clean fuel filter installed, start by using a 10mm wrench to crack open the little bleeder screw on top of the filter head. Then, pump the primer bulb until you see steady flow of clean fuel with no air in it coming out of that bleeder. The bulb should pump easily. Then, close the bleeder, and using a 17mm or 19mm (forget which) socket wrench, crack open the banjo fitting at the upper end of the fuel supply line running from the filter head to the IP, at the point where it enters the IP inlet. Repeat the same bleeding procedure, pumping until you see no more bubbles in that clear line from filter to pump and fuel is flowing freely out of the line union. Carefully re-tighten the banjo fitting (tight but don't overdo it or the hollow banjo bolt can break). Now, you know that you have clean, air-free fuel supply all the way to the IP. Next, pressurize the IP by pumping the primer bulb until it is difficult to squeeze, and then, using a 17mm open-end wrench, crack open each of the 6 injector line union nuts at the fuel injectors. With you standing under the hood and continuing to squeeze the primer bulb and watching the motor, have a helper sit in the car, hold the accelerator to the floor, and crank the engine with the starter until you see steady repeated spurts of fuel coming out of each injector union. At this point, stop cranking, tighten up each of the injector line nuts, hose the engine down with water to wash the excess fuel off of everything, and fire it up. It should start almost immediately.

This will put you back at square one, with a primed injection system. The next step, after you get the car going, will be to drive it a bit and determine if/where/how/why it is continuing to lose prime and/or develop a fuel supply restriction.

Let us know how it goes.
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86 745 D24T/ZF 345k lifted 2.5"
83 764 D24T/M46 155k
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