Is your low pressure line (the big one) condensating (getting wet) from your evaporator (black box on firewall) to the back of your compressor? Is there a steady drip out of evaporator to ground by front passenger tire? What’s air temperature coming out of your vents in the truck?
Have you tried rotating the engine with a ratchet to see if there is drag during the rotation. I wonder if one of the cylinders is rusted and your hearing that.
Put a temperature probe under your hood and you’ll discover that at speed your under hood temp is the same as outside temperature. There’s a lot of air coming through the grill of your truck. The heat comes in when turbo compresses the air, intercooler is the ticket. Your EGTs are pretty normal...
The powerstroke and idi both had serpentine pulleys but one was 7 ribs and the other is 8 ribs. If you use an 8 rib belt on a 7 rib pulley it will automatically adjust the belt to 7 ribs quickly.
Check the voltage drop across the glow plug relay. With a voltmeter set to dc, put the leads a the two large lugs on the relay. Have someone push the button and read the voltage. Should be less than 1 1/2 volts. If it’s more your relay is bad.
I put a 96 powerstroke pump on my 93 IDI. It did fit and worked. It’s been 10 years ago so it’s a little fuzzy. There was something different about the sequence I had to install the bolts to make it work.
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