Hi guys after replacing the pmd, the oil pressure switch, the glow plugs, the fuel filter, the starter, I am still getting stalling or no start. here is the diag list
0. Describe in detail the problem you are having. Please be as descriptive as possible.
1. Does the engine crank, or 'turn over'? yes
1a. Does the engine start and run? not always
1a1. If the engine does not start - Crack injector line: do you have fuel? Yes
1b. Do you have a Wait To Start Light & the amount of time (seconds) lit.varies from 1 sec to 20 secs
1c. Ambient Condition (temperature outside indicate F or C) ___varies -5 to +40__ °
1d. Engine Cranking speed (if you have an accurate tachometer).
1e. Are you experiencing stalling? yes
1f. If Stalling, describe (upon startup only, down the road, hit a bump etc) start up ,driving
1g. If Stalling, do you notice loss of dash or instruments? no
-note if experiencing stalling,you must indicate PMD location in #24.
1.1 Lift pump test - describe results pass
2. Service Engine Light while running?- on/off/intermittent no
2a. Service Engine light does glow during start/cranking/bulb check: Yes
3. Model year 1500 1996 tajoe 6.5
3a. Odometer reading (indicate if in miles or km) 440 kms
3b. Miles on major engine components if been replaced (example Injection pump) roughly 100 kms
3c. Indicate the model number on the Injection pump (starts DS4 or DB2......)
4. Have you scanned for engine codes? (varies by pre/post 96) yes/non yes p0251
5. List exact results on engine codes:
6. Air Filter condition (visual check) cleaqn new
7. Fuel filter condition (freshly changed/condition unknown/mileage since changed) new
8. Condition of Battery terminal connections (removed, cleaned and tightened)
8a. Known condition and age of the batteries. new
8b. Are batteries of differing age or are they a matched set? matching
8c. Condition of Major Grounds. (same drill as batt - removed, cleaned, retightened) all grounds cleaned
9. Upon cold start, does the radiator hose get hard quickly? no
10. Upon cold start, do you have excessive white smoke? Yes/no
11. Do you have excessive cranking time before the engine starts? yes
12. Have you used the block heater, and does this effect engine starting?(only try for starting problems) sometimes helps

sometimes doesnt
13. During hard acceleration, do you have excessive black smoke? sometimes
14. Do you have any unusual exhaust smoke issues? white on start up at times
15. Turbo check out - pass
16. Do you have an EGR on the engine? (An F or an S engine code 8th VIN digit)
17. Indicate if you know if it’s a 1500, 2500, 2500HD, 3500, 3500HD.
18. Indicate fuel that you are using: Bio-diesel, #2 Diesel, #1Diesel, SVO/WVO, other diesel
18a. If running a VO (Veggie Oil fuel) setup, indicate details of your conversion (homemade, or packaged system)
19. Are you using any fuel additives? If so, please list. kleen flo injector cleaner
20. Please indicate geographic region you are in: (example: Texas or Canada) toronto canada
21. Do you have any service history available that might pertain to the problem you are having? no
22. Please indicate any modifications to the vehicle that might help us diagnose better.
23. Upon unscrewing the fuel cap, do you have a large vacuum formed in the tank? no
24. Location of PMD/FSD? On the pump/remoted over intake/remoted out of engine bay (please specify placement specifically)
24a. If remote mounted, describe wiring harness (homemade or purchased from a vendor?)
24b. Indicate the location and condition of the FSD/IP grounding wire.
25. Are ALL glow plugs in proper working order as per this thread? far as i know all seem fine

there is fuel getting to the filter as it comes out it also comes out the t bar when i open it, i have a code p0251 periodically and now i am not sure how to diagnose this code. any help greatly appreciated as i am about to blow this thing up as my patience is running things changing parts as per suggestions. But dont get me wrong I do appreciate all the help I get

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Where is the PMD/FSD mounted now?
Has the ground for the PMD/FSD been removed and cleaned, is it still on the IP?
The PO0251 indicates an OS problem, if I remember correctly.
Does the unit have a filter resister inline to the OC on the IP?
The filter pack if there is usually under the intake manifold more to the passenger side.

pmd mounted on the plenum, not sure what you mean about the passenger side more thing, i have cleaned all the grounds, this is the first time I Have recieved this code but have had all the symptoms all along before i have replaced the mention items, it is a 1996 tahoe 1500 by the way

bad place on plenum or anywhere under hood for that matter, need to get it out of engine bay, is this a SS Diesel kit, if so you'll also want to reconnect the ground to the IP they have you remove and put on the cooler. Pass side is another underhood location reference

Did you buy a new PMD or one of those "good" used PMD?

Fill this link out: http://dieselplace.com/forum/profile.php?do=editsignature

As TD said have a look in the 6.5 FAQs (http://dieselplace.com/forum/showthread.php?t=53309)
Heres a photo of the OC filter http://dieselplace.com/forum/attachment.php?attachmentid=29279&d=1164349095

Look for the injection pump center front engine under the intake manifold just to the (pass side) should see the IP with a connector on it and possibly the OC filter.

there is fuel getting to the filter as it comes out it also comes out the t bar when i open it, i have a code p0251 periodically and now i am not sure how to diagnose this code. any help greatly appreciated as i am about to blow this thing up as my patience is running things changing parts as per suggestions. But dont get me wrong I do appreciate all the help I get

I was getting that p0251 code but I was only getting it with a p0335 code which is the crankshaft position sensor. I replaced the sensor and neither codes have turned on since. since the 335 code isnt showing up Im not sure if this helps but Im just passing on some info to you.

I had the exact same problem as you, with the PMD mounted to the intake with a heatsync. It lasted 4 months there, and had to replace it with an out of engine location. (Heath Diesel's Kit).

Just because you replaced your PMD doesn't for sure mean that it is good, if in fact it is till in the engine bay.

NOt saying that is defanatley the problem, but it defanately was mine.