I just finished installing my 4kgsk and the plug that allows access to the internals of the pump will not fit back in the same hole for the life of me. Ive tried all different angles and cleaned the threads I'm about ready to Sh*t a brick. Has this happened to anyone else?

 

I go through the top. That plug is a real pita. Just keep trying, eventually it will go.

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I honestly can not imagine how that is easier.... I have done it through the plug on less trucks than you, but I feel safe saying I am proficient in it.

you have to move the fuel shutoff lever up and down. I ended up un-bolting the last one I did in order to get the cap to thread back on.

I am referring to the part in the bottom right corner of this picture. the shutoff solenoid attaches to this....

 

I eventually got it. Put everything back together, now my truck won't idle, yes it's an auto. Did some searching, said either I left the shims in, or I need to tighten the springs. Honestly, I dug and dug with the magnet and the screwdriver on my truck and I couldn't find any shims. I called the Tech-line where I bought them at Pure Diesel Power, and the guy said it was possible I didn't have any. I find it hard to believe that I didn't have any shims at all, but none stuck to the springs and I couldn't dig any out even though I tried.
So, problems and solution correct me if I'm wrong.
A. Springs are too loose, tighten springs and measure them with a micrometer until I'm sure they are the same measurement between 40 and 50.
B. Keep digging for shims and repeat .A.
C. Increase Idle
D. Give up and find a shop somewhere near Austin TX I can trust
E. Get drunk and wash it and stare at it.

 

as long as you are sure that the springs are equally tightened, raise the idle.

my 96 had no shims and idled real low when putting in the 4k kit and putting the nut back to the "factory" position.

 

Be cautious when adjusting away from the factory measurements. There's nothing saying the studs are the same length. As Benji said, might adjust idle and if that doesn't help tighten the exact amount on both sides. If their to tight they'll cause a very touch throttle pedal. Make sure you go from the top. Much much less frustrating.

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Thanks for the help guys. I went back and re adjusted the springs, the micrometer method is useless I can't get a good measurement at the angle at all. I tightened them 4 clicks on each side (from what I could feel). It ran good for about the first 5 mins of driving. Then idle went back down to low, and it almost seems to be surging a little bit when its running. I opened the hood and noticed smoke from the back driver side, opened oil fill and it was smoking (not puffing) like a chimney, I'f I completely screwed up my motor somehow doing this I might Just cry for probably the 2nd time as a grown man. Could the smoke be caused by the g-springs messing up a valve alignement? I only revved it to about 2.5k as that's all that seemed safe and I have stock valve springs. Its never seen over 35psi boost. I have gauges and everything and it reached 1300 on the egt once, and only once for maybe a second. I've babied this thing and I'm really worried. Break it to me, whats going on?

 

sounds like a case of blowby. there is a tube that hangs below the motor that vents the crank case vapors.

IMHO, there is NO WAY that the GSK could cause what you describe.

is everything else stock on the truck?

 

It's got a zero plate and a boost elbow. The thing that's weird is there is no pressure with the smoke. If you put the cap on it it wont blow it of or move it, or feel over it you can't feel any pressure at all, it doesn't puff with the motor like blowbye normally does its just a steady stream. It only started after the gsk I don't know how it could have caused it. It's never had it before like I said. Accept one time after I got the oil changed at a shop, didn't specify what to put in, and they weren't a diesel shop, it had a little after that, then I put 15/50 mystic in it and the smoke stopped, now its back after the gsk.

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Does anyone else have any more imput? I'm having trouble understanding how my minimal modifications could have caused blowby. Truck has 265k. Always had oil changed on time.

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Any other thoughts you guys?

 

I would be looking for a leak or a kinked draft tube before I got too excited. Instant blow by is fairly rare. Its possible something happened to a piston ring just by coincidence, any time you modify a vehicle beyond stock parameters failures are possible. Rare but possible. Didn't drop anything in the pump did ya? No new oil leaks?

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