So I needed some help figuring out my vacuum line routing to my EGR valve/Air Cleaner Bi-Metallic Valve. There's only four vacuum lines total in this thing...and I know I can't be this dense...but essentially the only lines that make spatial sense for hooking up are the A/C B/M to the EGR Valve. Except that the A/C DV line is way too big for the EGR valve and makes no logical sense to hook it up to an EGR valve. They both need vacuum...and neither will provide it. The vacuum diagram under the hood (which I will provide for you in a second with some goofy MS Paint explanations) shows a red line coming from the MAN Vac and going to the EGR Solenoid, then a green line going from that to the EGR valve. But the red and green lines are factory wrapped back to the MAN Vac, the green one will reach the EGR Valve...but it is rediculously oversized. The line that I remember fitting/going to the EGR valve is the one I have hooked up to the Fuel Pressure Regulator that comes out of the middle of the MAN Vac currently and nothing else seems to be able to go to the Fuel Pressure Regulator, and according to the diagram there aren't any more lines.
1.) Is the line from the middle of the MAN Vac okay to go to the EGR?
2.) Should I try to make this green line work with an adapter because that's what the diagram shows?
3.) Can I run a new line from an empty port on the MAN Vac to the Fuel Pressure regulator?
4.) Do you think for some reason there'd be a fifth line coming out of the woodwork I should look for? Perhaps something from the intake manifold or a charcoal cannister or something that would go to the fuel pressure regulator? Or would they all be related to the MAN Vac and there's no vacuum anywhere else?
5.) Should I just hook up the AC/DV anywhere on the MAN Vac? Does it go somewhere on the air intake or manifold?
6.) Would the MAN Vac have separate sections of vacuum within it, perchance that the upper rung of vacuum ports might allow the EGR wires to do their work with the EGR while the lower ports might be lone sources of vacuum and could easilly go somewhere else without affecting the EGR Valve?
7.) How did things go so terribly wrong that I'm debating removing vacuum plugs from my MAN Vac when clearly I didn't have to before? That means there's loose vacuum ports/lines just hanging out somewhere under the bread tangle of factory wiring.
The boring story:
So...I just got done rebuilding my little 2.3L from the block up (after 200,000 miles and some serious hunting abuse from me/whatever the people who had it before me did to it...). The head was cracked in three places, valves bent, EGR ports, exhaust ports, water ports completely plugged. I'm surprised it was even still running and got me up into the mountains without much complaint. Cylinders all still had amazing compression and good rings, so I left all that alone. I found a head with smaller valves for pretty cheap out of a '93 and had it machined. Apparently smaller valves give you some extra HP, so why not?
Anyway, end of my preamble: As I was tearing it down and neatly bagging and marking lines and cables with my father, I went to pick up my paycheck from work (to finance this little endeavour) and when I got back my engine bay was essentially empty. My dad's been a diesel mechanic for something like 40-odd years, so I didn't worry too much. But on putting everything back together we had random bolts, some bolts were too long, others were apparently in too shallow, a lot of them are mismatched, and it added hours to the project of just trying to figure out how things were supposed to be bolted, and that, if my dad had waited for me and neatly bagged and marked bolts, etc., it would've been easy as you please. Of course after 40 years as a professional mechanic maybe you just get overconfident...I'm a newbie and put masking tape with sharpie instructions on everything. EVERYTHING.
The engine runs great, and better than it did before it just...feels a little ghetto knowing the right bolts aren't in the right spots. But it's all solid/stable and nothing is in danger of causing a problem. Just feels ghetto.