Sorry, tried to post yesterday, wiped most of my information not sure how it posted. Anyway, I’m new to diesels, this is my first. Truck seems to run great overall, though I have never owned a 6.5 to compare to. I recently bought and have issues with excessive white smoke on starts, runs kind of rough, then smoothes out after about ten second or so and runs good. First I replaced glow plugs and connectors, did not replace controller. Glow plugs are receiving 10.5-10.7 volts each on start. Is this enough/could it be higher with new controller? Then I replaced both batteries with high cranking amp batteries and new starter. Motor cranks over faster, but still smokes. I then replaced injectors with rebuilds; thought might be leaking down overnight, still smoking. Once it got hot out (over 95 or so) here last couple months, does not want to start, just cranks and cranks, eventually it will start after several attempts, but always starts eventually. So, I relocated a used/ supposedly good PMD on a heat sink under the front bumper, still hard hot starts. I checked fuel pressure at t-valve, only 2-2.5 lbs. so replaced the fuel filter went to 3-3.5 lbs. replaced lift pump, went to 4-4.5 lbs. Recently I tried the water test I read about here on the Injection pump. Several different occasions I have poured water over the injection pump when hot, starts instantly. I’m thinking of replacing the injection pump; don’t know how old it is anyway. Could there be a component of the pump bad, sensor, etc. before I shell out the big bucks? Anymore test I can do? Also seems like idle is getting rougher lately. Currently still smoking on colds starts and hard hot starts. Getting 16mpg, sometimes better, dually, crew cab long bed, gas mileage not horrible, but though could be better. I appreciate any and all help. Thanks

1. Does the engine Turn over? YES
1a. Does the engine start? YES
1b. Do you have a Wait To Start Light & duration lit. YES
1c. Ambient Condition (temperature outside) 65-95+F
1d. Engine Cranking speed (if you have an accurate tachometer). GOOD
1e. Are you experiencing stalling? NO
1f. If Stalling, describe (upon startup only, down the road, hit a bump etc)
1g. If Stalling, do you notice loss of dash or instruments?
-note if experiencing stalling,you must indicate PMD location in #24.
1.1Lift pump test (http://dieselplace.com/forum/showthread.php?t=39350)- describe results 5 LBS
2.Service Engine Light - on/off/intermittent OFF
3.Model year
3a. Odometer reading 208,000
3b. Miles on major engine components if been replaced (example Injection pump) NEW INJECTORS, INJECTION PUMP?
3c. Indicate the model number on the Injection pump (starts DS4 or DB2......) DS4 5521
4. Have you scanned for engine codes? (varies by pre/post 96) yes/no YES
5. List exact results on engine codes: NONE
6.Air Filter condition (visual check) CLEAN/REUSABLE
7.Fuel filter condition (freshly changed or condition unknown) NEW
8.Condition of Battery terminal connections (removed, cleaned and tightened) GOOD
8A.Known condition and age of the batteries. NEW
8B.Are batteries of differing age or are they a matched set? MATCH
8C.Condition of Major Grounds (http://www.dieselplace.com/forum/showthread.php?t=157085). (same drill as batt - removed, cleaned, retightened) GOOD
9.Upon cold start, does the radiator hose get hard quickly? Yes/no NO
10.Upon cold start, do you have excessive white smoke? Yes/no YES
11.Do you have excessive cranking time before the engine starts? WHEN HOT
12.Have you used the block heater, and does this effect engine starting?(only try for starting problems) HAVE USED HEATER/SAME
13.During hard acceleration, do you have excessive black smoke? Yes/no NO
14.Do you have any unusual exhaust smoke issues?
15.Turbo check out (http://dieselplace.com/forum/showthread.php?t=39368)- pass/fail PASS
16.Do you have an EGR on the engine? (An F or an S engine code) F
17.Indicate if you know if it’s a 1500, 2500, 2500HD, 3500, 3500HD. 3500
18.Indicate fuel that you are using: Bio-diesel, #2 Diesel, #1Diesel, SVO/WVO, other #2
18a. If running a VO setup, indicate details of your conversion (homemade, or packaged system) N/A
19.Are you using any fuel additives? If so, please list. DIESEL KLEEN
20.Please indicate geographic region you are in: (example: Texas or Canada) SOUTHERN INDIANA
21.Do you have any service history available that might pertain to the problem you are having? NONE
22.Please indicate any modifications to the vehicle that might help us diagnose better. 4” EXHAUST, NO AIR BOX/REUSABLE FILTER
23.Upon unscrewing the fuel cap (http://dieselplace.com/forum/showthread.php?t=42338), do you have a large vacuum formed in the tank? yes/no SLIGHT HISS
24.Location of PMD/FSD (http://www.dieselplace.com/forum/showthread.php?t=39436)? On the pump/remoted over intake/remoted out of engine bay (please specify specifically) UNDER FRONT BUMPER
25.Are ALL glow plugs in proper working order as per this thread (http://www.dieselplace.com/forum/showthread.php?t=39182)? YES

Mine was having ahot start issue as well so I changed all the return hoses on the injectors and the rubber fuel lines coming from the filter base to IP. Worked for me.

" I recently bought and have issues with excessive white smoke on starts, runs kind of rough, then smoothes out after about ten second or so and runs good"

I just bought mine too and am getting similiar cold starts. Warm starts no smoke at all. With cold start your relying on the glow plugs only for ignition of cold fuel, this maybe normal.

But hot starts you do have a problem, does it stall on you at all? PMD would be the most likely component after the things that you have already replaced.

You have relocated it which is good but if already failing it was too late.

I failed to mention I had replaced return lines while replacing injectors, but not fuel lines coming to filter base, is this an issue?

But hot starts you do have a problem, does it stall on you at all? PMD would be the most likely component after the things that you have already replaced.

Mudbath, it has never stalled