... that the upper and lower intake needed to be removed to replace the stock pmd wire harness with my new six-footer. WHAT A PITA, at least for a "wanna be shade-tree" mechanic. However, looking at the bright side, it sure made removing my pmd from the pump easy. One of the transistor caps just fell off as I lifted the pmd from the pump, and I noticed three of the four transistor nuts were loose as a goose. Who knows? Maybe it'll make a decent spare.http://www.dieselplace.com/forum/smileys/smiley2.gif


Since I didn't have a new lower intake gaskets, my truck had to spend the night in my dad-in-law's shop, blocking in his "haul-the-grain-wagons-to-town" tractor. I'm praying for crappy weather tomorrow, or else my dad-in-law will have to pick up all the little parts and pieces from under the hood, throw them in a bucket, and tow my burb outta the shop so he can get his tractor out to haul grain to town. I got my fingers crossed, but don't tell the farmers!


Hopefully, if I'm lucky, tomorrow the local dealer will have the gaskets in stock, and TDG's pmd will arrive.http://www.dieselplace.com/forum/smileys/smiley4.gif


BTW: Pulling those little resistors outta the pmd's in a PITA too! I ended up making a tiny hook out of a paper clip to get them out, but it still took a lot of patience.

could you possibly take some pics for us of this process of relocating the PMD?


Im a huge visual person...lol

Sure. I'll try and remember to haul the camera out there tomorrow evening. But there ain't much to see but a big friggin mess under the hood and a missing grill (which I'm thinking about painting white, since the chrome is starting to peel and I have factory matched white spray paint sitting in the basement begging to be used).Edited by: w_huisman

i just made my own 6ft extension, as an experiment, but haven't had the enthusiasm to
install it yet, knowing now I have to pull everything off to get the
new harness plugged in.

went to my local Stanadyne shop, who sold me the FSD cooler last
year, and asked for an old OEM harness, and he gave me 2 new ones
to play with...no charge....cut one in the middle, added 6 ft, soldered
all the connections, and new heatshrink and loom...so i'm good to
go...except for the labor.



now when I look at the picture of the extension harness on JK's site,
it looks like you just plug it in to the existing 10in. OEM harness w/o
having to remove the manifold...(assuming you don't have to get the PMD
off the pump ) ....can anyone confirm ? maybe this is the simpler way
to go for those of us less inclined to dismantle parts, and replace
gaskets.




Edited by: steve-r

Steve-r,

you can unplug the OEM harness from the PMD on the pump without dismounting the manifold. In case the plug on the OEM harness fits into the plug of your extension, you can just plug the extension in in place of the PMD.

Be careful when you unplug the OEM harness, the plug is secured to the PMD so that it cannot come off accidentially. You´ll need thin fingers to get at the plug :)

Steve-r,
you can unplug the OEM harness from the PMD on the pump without dismounting the manifold. In case the plug on the OEM harness fits into the plug of your extension, you can just plug the extension in in place of the PMD.



Man, wouldn't that be nice! But there's no way to make a home made extension with a female pmd connection because the only one available is part of the pmd.

i just made my own 6ft extension, as an experiment, but haven't had the enthusiasm to install it yet, knowing now I have to pull everything off to get the new harness plugged in.
went to my local Stanadyne shop, who sold me the FSD cooler last year, and asked for an old OEM harness, and he gave me 2 new ones to play with...no charge....cut one in the middle, added 6 ft, soldered all the connections, and new heatshrink and loom...so i'm good to go...except for the labor.





Steve What would be the chance of getting another couple of old harnesses. I would like to do as you have so I don't have to cut the wiring on the truck.

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&amp (http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&category=33553&item=7931649 058&rd=1) ; ;category=33553&item=7931649058&rd=1


$4.99 + shipping. I bought one of these, and I got a brand new one with an old injection pump I bought to tinker around with. I built my harness just like steve said too. Spent all of last Saturday afternoon working on it.


Now I'm going to spend all of this evening putting my darn truck back together. My wife will love that (sarcasm).http://www.dieselplace.com/forum/smileys/smiley7.gif I'm not looking forward to it, but hopefully it'll go well.Edited by: w_huisman

Bowtie, I see you acted quickly on that ebay harness...well done!



Olee,...what Wade said...if you make your own, you'll see that the male
& female plugs on the OEM aren't a match. the OEM harness end that
plugs into the PMD is male, and the female receiver is integrated onto
the PMD. the gray female plug on the harness plugs onto the pump
and it has different pins inside. what we need is a female plug end
that matches but is separate from the PMD..that is what I think
Kennedy has used.


Edited by: steve-r

http://www.dieselplace.com/forum/smileys/hihi.gif

I got a new harness with my new PMD. So, I simply cut and soldered mine together, as the thought of added resistance due to connectors kind of worried me. It is not fun to pull the intake, but you should only have to do it once. If you need to extend your harness again at some point you can always cut solder and weather-proof shrink tube it. FYI avoid using poly shrink tube under the hood or outside the vehicle. It is not hermetically sealed and will hold moisture and corosion inducing chemicals on the joint. Just my two cents.

Put Gray RTV for emissions sensors on the solder joint, push the heat shrink sleeve over it and apply heat - wipe off excess RTV and allow splice to finish cure.


And remember - this is the second time you saw it here, first.

5 minutes to unplug the OE connector and plug in my extension. No intake removal, and just abandon the old PMD and resistor there. Heck we even have a kit with EVERYTHING so you can be ready to roll in about 1/2 hr...

purchase pmd harness ($20)


3 hours to build my home-made 6-ft harness (free)


5 hours to install my home-made harness. (free)


Intake gaskets ($20)


1 known good pmd and 3 spares ($65)


Kennedy FSD heat sink ($65)


TOTAL $175...


I still have over $300 to spend before I have invested what your pmd kit would have cost me. Plus I enjoy tinkering around with this stuff and value the learning experience. It's a good chance to get to know my truck better.Edited by: w_huisman

purchase pmd harness ($20)


3 hours to build my home-made 6-ft harness (free)


5 hours to install my home-made harness. (free)


Intake gaskets ($20)


1 known good pmd and 3 spares ($65)


Kennedy FSD heat sink ($65)


TOTAL $175...


I still have over $300 to spend before I have invested what your pmd kit would have cost me. Plus I enjoy tinkering around with this stuff and value the learning experience. It's a good chance to get to know my truck better.








I think John charges $90 for just the harness so you could have saved $40 and the harness would have only cost you $50.


Maybe 7 hours of your time isn't worth $50 to you?

Yeah, good point. Again... "I wish I had known..." ahead of time that his harness would have saved me from removing the intake. I would definitely have gone that route.


Live and learn, I guess.

> But there's no way to make a home made extension with a female pmd connection because the only one available is part of the pmd.

Ja, but somewhere all these plugs must come from ...I´d like to get a set or so of them, you never know when you need them. The plug on WG solenoid is already gone on mine for the wire was broken too close to the plug to repair it.

Anyway, with only the upper intake removed, the plug can be cut off and wires soldered in. Though accessing the harness still isn´t exactly easy, it can be done without a need to remove the lower intake.

Otherwise, if you can get it, a pre-made harness isn´t a bad idea :)

Bumpin'Yota, I'm sorry I forgot to take the camera along to the shop last night and didn't get any pics.


Truck is back together and seems to be running like a top again. But could someone please post a picture of the top of their motor. Specifically, I would like to see how/where all of the brackets, ground cables, etc. are supposed to be bolted to the lower intake bolts. Especially those little brackets that wrap around the injection lines, holding them in place.


Thanks!Edited by: w_huisman

> Ja, but somewhere all these plugs must come from ...IŽd like to get a set or so of them,




i agree...they're somewhere...I was searching through the Delphi site
yesterday, saw some similar but there are 1000's of different kinds.
they make automotive connectors, just a matter of finding the needle in
the haystack .

Have you guys even looked at my harness? The female end is custom built. Stanadyne moulded the female into the PMD itself. We take 2 like connectors and mate with a coupler...





FYI, I have a box full of NEW Stanadyne pump harnesses available. I also MAY have some of the hollow female couplers available too...

John, yes, I surf your site and drool regularly. its a candystore for 6.5 owners!

You have the ideal harness extension solution, no question. I really want to avoid pulling the top off my engine if I can.



For me, its less the money, and more the "hunt" ....if I could
find a lowcost female connector like the one on the PMD by searching
the net for an hour, it would be ideal.....but unfortunately I found
1000's and no way to narrow it down easily.....so its coming down to
pull the top and install what I made, or call you and keep life
simple......decisions...decisions..http://www.dieselplace.com/forum/smileys/smiley5.gif

John, decision made.. order just placed on your site. sure as heck if i
pull the top apart, I'll break something. plugging in your cable is
lower risk, at least for me.

Steve you didn't go wrong I have John's extension on my turck works well, best part it maintains the weatherpak seals

I just want to clarify that the surplus "couplers" that I have will NOT complete the project. One of the OEM style plugs will need pins soldered into it in order to make the connection.





We went to a molded coupler with the pins set into an epoxy for the latest production units.