OK, here's what I think was happening. After having a discussion with Chance, he said my idling problems sounded like a vacuum leak. So, I checked all the connections and still had the problem. I then started to examing the
check valve--it looked like some debris was caught against the rubber ball. I removed the
check valve and blew some compressed air through it in the direction of water flow. Then, to make sure, I disassembled the
check valve and found it to be a simple spring and ball valve. I reassembled everything and reinstalled the valve. No more idling problems.
I also added over a quart of fluid to my washer tank after driving only about 35 miles. I'm now believing that the
check valve was leaking all the time and consuming fluid continously when under vacuum (which is probably 95% of the time). When driving, I didn't notice the leaking water, but at idle I did.
For extra credit, I soldered the green wire to the MAP signal wire instead of using the quick connector. I was told that will probably eliminate the random short bursts of the pump.
Haven't taken it for a test drive, but will report back when I do. I did order a 2 gph nozzle because of the proximity to the intake. I'm more concerned with knock suppression than cooling the charge.
Keeping my fingers crossed!