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I'm always grateful to hear any final outcome post that accurately explains the original symptoms. Noticed your sig and the 5 240s. We and the kids have eight all told, but it was the very first one that goaded me into obtaining a way to measure fuel pressure at the rail. I am always surprised by the disparity between the money that goes into guesswork replacement parts compared with that spent on diagnostic tools and literature.
I spent (or wasted) a lot of time rummaging through the fittings at auto parts stores looking to match those M14 line connections to a pressure gauge, before finding this forum. The suggestion I received was to make an adapter from a junkyard rail. Now that I have it, pumps, check valves, leaky injectors and defective FPRs don't dare enter into our maintenance mysteries.
By the way, rebuilt parts are not to be trusted: consider the economics of the reman industry- originator of the "lifetime" guarantee.
Again, anyone who helped on this is grateful for the feedback, as am I, even though I missed it.
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Art Benstein near Baltimore
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