You just have to be very careful pulling and installing the top cover, I always leave the governor spring assembly and throttle shaft with the main body of the pump, but since the manual shutoff lever is on the top cover you have to weasel it past the spring cage, I found you need to manipulate the manual shutoff lever while removing and installing the top cover. I tell you it’s sooo much easier to do on a Cummins VE pump since they have the other style spring.

I started wiring the glow plugs (thanks George!) and the tach, it all works! Now I just need to tidy it up. I’m in the process of building an aluminum battery tray also.

Tell me about the battery tray. I need to do something for my (50% gone) battery tray.

I would replace yours with a factory composite one. I have to build mine because I will not be moving the washer bottle. I finally got around to building one, it’s not yet installed though.

It now has exhaust! All 7.3 power stroke exhaust parts! Performance OBS downpipe modified for the Volvo, from the downpipe back is all used 3.5” from a 2002 E450.

Picture of entire exhaust.

Looks like that OBS downpipe fit nicely. What did you have to do to it to get it to line up that well?

I cut about 10” from the turbo side and welded a 2.5” v band on it, rotated the two 45* pipes to the configuration that fit and installed a 3” v band to the end, I didn’t expect it to fit as well as it does!