I am completely lost with my truck ... I bought it a little over a year ago from a guy that couldn't diagnose a problem with the truck dieing on him but said he had fixed the problem ... Just before I bought the truck he said he had just relocated the PMD, installed a new IP and lift pump, And replaced the ECU ... I had the truck a couple weeks and it just died on me at a redlight ... I had the truck towed home and started checking things and the fuel filter was clogged ... So I tore into the fuel system full force by dropping the tank, flushing it and having it coated ... I flushed the fuel lines and replaced the filter ... The truck has ran like a champ for a year ... I was driving it the other week and it died on me just like it did with the stopped up filter ... This time the truck just fired right back up and I drove home ... The filter was dark colored but didn't have trash in it but I changed the filter anyhow ... A couple days later it died while sitting on an incline and I thought I didn't get all the air out of the lines ... It was a little hard to get it started back this time tho ... After I opened the valve on the engine to make sure all the air was out of the fuel system I went on my way with the truck ... A couple days later it just starts dieing at random times and becomes increasingly harder to start ... While I was trying to start the truck one day it would idle for a minute and just die ... When I would try to get it to restart I would check and make sure the lift pump was running and the engine would turn over and wouldn't fire ... When it did fire a puff of black smoke would come out of the tailpipe like I had just floored it ... My mechanic said he can't pull any codes on the truck ... The previous owner said the engine was a 97+ model with around 75,000 miles on it and the mods are in my sig ...

Good detail in your description, Slamson... thanks

You're gonna hate this, but go through the checklist, one item at a time, and post the results back here. Pay particular attention to the Lift pump test... I'm curious about whether your LP runs while the truck is idling, and what pressure it puts out (if you have a small gauge you can attach to the drain line (brass T-handle) that would help.

Would also be a good thought to maybe put a clear lint into the fuel circuit right before the IP so look for bubbles in the fuel.

Some of the guys around here are amazing at diagnosing fuel issues once they get a little more information, so try to be specific and clear, OK?

Jim

:Get_him:Would also be a good thought to maybe put a clear lint into the fuel circuit ,,

LOL Most of my LINT is fuzzy,,, HA HA HA lets all read LINE here. Sorry Jifaire,, buy I'm in a silly mood!!!

Smart-Alice.. so I can't type or spell... :) Nice catch.

I hate it when you type something wrong, but it's still a valid word, and the spellchecker ignores it.

'cause I can't proof-read, either. :)

:hug: It's ok,, We still love ya!!! Eh! :rotflmao:

Note: blue text is JiF edit. Slamson responses in Red

I'll go though the list as I can on the items I have already checked ... The truck is at the garage and I can't check some of the stuff on the list until Monday or later ...


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? Yes, or atleast until it dies
1a1. If the engine does not start - Crack injector line (http://www.dieselplace.com/forum/showthread.php?p=2188140#post2188140): do you have fuel?Yes/No Yes
1b. Do you have a Wait To Start Light & the amount of time (seconds) lit. Yes
1c. Ambient Condition (temperature outside indicate F or C) _____ ° Low 90's the last time I worked on it
1d. Engine Cranking speed (if you have an accurate tachometer). not relevant to this issue
1e. Are you experiencing stalling? Just like I cut the ignition switch off
1f. If Stalling, describe (upon startup only, down the road, hit a bump etc) Tried to describe in the original post
1g. If Stalling, do you notice loss of dash or instruments? Just like the switch was cut off Still need to know if the dash instruments quit. Do the warning lights come on? What about the fuel gauge?
-note if experiencing stalling,you must indicate PMD location in #24.

1h. Check turbo inlet and air filter for obstructions. Cone filters have lost disk and stopped air to turbo. All clear and clean
1.1 Lift pump test (http://dieselplace.com/forum/showthread.php?t=39350)- describe results I still need to check the connector and the fuel pressure but the LP does run need to do more testing on this
2. Service Engine Light while running?- on/off/intermittent Service Engine is off
2a. Service Engine light does glow during start/cranking/bulb check: Yes/No Yes the light works
3. Model year 1996
3a. Odometer reading (indicate if in miles or km) 180,000ish
3b. Miles on major engine components if been replaced (example Injection pump) IP, LP, PMD, And computer all have been replaced in the last 5,000-6,000 miles
3c. Indicate the model number on the Injection pump (starts DS4 or DB2......) I'll have to check Never mind... yours is a DS-4
4. Have you scanned for engine codes? (varies by pre/post 96) yes/no Yes
5. List exact results on engine codes (http://www.dieselplace.com/forum/dtc.php): None
6. Air Filter condition (visual check) Clean
7. Fuel filter condition (freshly changed/condition unknown/mileage since changed) Less than 100 miles and clean
8. Condition of Battery terminal connections (removed, cleaned and tightened) Clean and tight
8a. Known condition and age of the batteries. 1 year old
8b. Are batteries of differing age or are they a matched set? Matched set
8c. Condition of Major Grounds (http://www.dieselplace.com/forum/showthread.php?t=157085). (same drill as batt - removed, cleaned, retightened) Clean and tight
9. Upon cold start, does the radiator hose get hard quickly? Yes/no Haven't checked Not relevant to this issue
10. Upon cold start, do you have excessive white smoke? Yes/no A "puff" of light smoke as soon as it fires
11. Do you have excessive cranking time before the engine starts? Only after the engine dies
12. Have you used the block heater, and does this effect engine starting?(only try for starting problems) Never used it
13. During hard acceleration, do you have excessive black smoke? Yes/no Just for a moment
14. Do you have any unusual exhaust smoke issues? No
15. Turbo check out (http://dieselplace.com/forum/showthread.php?t=39368)- pass/fail Not relevant to this issue
16. Do you have an EGR on the engine? (An F or an S engine code 8th VIN digit) I haven't thought to check You have an 'F' as your eighth digit, so you have no EGR.
17. Indicate if you know if it’s a 1500, 2500, 2500HD, 3500, 3500HD. 3500HD
18. Indicate fuel that you are using: Bio-diesel, #2 Diesel, #1Diesel, SVO/WVO, other Diesel from the gas station
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. Lucas oils Diesel addative
20. Please indicate geographic region you are in: (example: Texas or Canada) South Carolina
21. Do you have any service history available that might pertain to the problem you are having?Not relevant to this issue
22. Please indicate any modifications to the vehicle that might help us diagnose better. Mods are in my sig
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 No
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 placement specifically) Relocated behind the bumper on a heatsink
24a. If remote mounted, describe wiring harness (homemade or purchased from a vendor?) Purchased from vendor which vendor? if the harness has issues, then your PMD will have issues. Might want to try moving it back to the original connection if problem can't be narrowed down further.
24b. Indicate the location and condition of the FSD/IP grounding wire. Ground wire should still be on the IP... if your heat sink says 'Heat-Sync" on it, check to make sure the ground wire hasn't been lengthened and attached to it.
25. Are ALL glow plugs in proper working order as per this thread (http://www.dieselplace.com/forum/showthread.php?t=39182)? Have not checked the Glow plugs yet Not relevant to this issue

Thanks, slamson... definitely sounds like fuel. We need you to check the LP... not that it's running, I know you did that, but that it's pumping (there's a difference). If the LP runs while sitting still with the truck off, but not when it's idling, then your OPS is shot, or at least needs work.

If you continue to get clean TO the IP, and not the injectors, then it's likely your PMD needs attention. Do you happen to know if the Previous Owner put a new PMD on, or a used one, or just moved the old one to the bumper?
Putting the clear line in before the IP will let you see if there is any air in your fuel system... bubbles in the line will show you that, but it's unlikely, as it would run crappy, not just shut off. I'm more inclined to think PMD than anything, at this point.

As for the checklist, I edited it a bit (in blue) for things that you don't need to worry about filling in later..

Thanks, slamson... definitely sounds like fuel. We need you to check the LP... not that it's running, I know you did that, but that it's pumping (there's a difference). If the LP runs while sitting still with the truck off, but not when it's idling, then your OPS is shot, or at least needs work.

If you continue to get clean TO the IP, and not the injectors, then it's likely your PMD needs attention. Do you happen to know if the Previous Owner put a new PMD on, or a used one, or just moved the old one to the bumper?
Putting the clear line in before the IP will let you see if there is any air in your fuel system... bubbles in the line will show you that, but it's unlikely, as it would run crappy, not just shut off. I'm more inclined to think PMD than anything, at this point.

As for the checklist, I edited it a bit (in blue) for things that you don't need to worry about filling in later..


Thanks for the help jifaire ... The previous owner said he put a Heath Diesel relocation kit and new PMD on the truck a few months before I bought it ... I still have the old/spare PMD in the glovebox, So I could throw it on and see what happens ... I'll have to check the OPS next week when I get back to the truck, But I had my brother cycle the LP for me when I opened the valve on the filter canister to make sure all the air was out the system ...

I'd pull the FSD (no longer a PMD) cables and check for corrosion, bent pins, not really plugged in very well (might be missing the TyRap at the FSD), dirt, etc. Were the screw holes filled with silicone and the body of the FSD sealed at the heat sink? If not water might be your problem. You might be able to dry it out and away you go if that's the case.
The above advice about the location of the FSD ground cable is solid. Make sure it's on the pump, not the heat sink.
Check the engine and chassis grounds too - They're a weak part of these trucks.

If it is the FSD, call Heath - I'd bet that they'll fix you up. Note: I can't, and don't, speak for Heath; but they are good guys.

That is one great thing about heath! He has the best customer service of any buisness I have ever seen. If it really is a heath PMD/FSD than call him up.

I had a few minutes yesterday to look at the truck ... The harness is wrapped in wire loom and I found a spot that looks like it melted and was taped up ... the plugs and pins look to be in good condition and the FSD/PMD appears to be sealed to the aluminum heatsink ... I'll check it out closer when I have the time ... But I think my problem might be where the harness has gotten hot and melted ...

The harness has melted where it goes under the Rad. support to the module tucked in behind the bumper ... I have checked Heath Diesel's website and they don't list just the harness for sale ... Anyone know if I can get just the harness anywhere? ...

The harness has melted where it goes under the Rad. support to the module tucked in behind the bumper ... I have checked Heath Diesel's website and they don't list just the harness for sale ... Anyone know if I can get just the harness anywhere? ...

Call heath and see what he can do for ya. I'm sure that he will help you out. What caused it to melt was it pinched.

Call heath and see what he can do for ya. I'm sure that he will help you out. What caused it to melt was it pinched.



It's hard to tell but I don't think it's been on the truck long enough for it to rub a bare spot ... I bought the truck with the relocation kit already installed ...

Hello,I'am also dealing with the exact problem you are describing.My pmd is mounted on the intake,Good batteries,can here lift pump run,new fuel pump relay,no check engine light.no fuel leaks,new fuel & air filters,good glow plugs. It started stalling about 8 months ago.Its like you are turning off the switch.It will go weeks with out trouble then all the sudden it will stall for no reason.Start stall start 2 or 3 times in row then run like nothing happened.It might do it shortly after starting after its been sitting for a while or it will happen after running for hours.And then sometimes I'll drive for a mile,stop for 15 min.Then it won't start at all.Soon as I try to Trouble shoot the wiring or fuel flow it will start right up and run fine for days.I can,t find any loose damaged wires.But I Have'nt checked the other grounds. Buck

Hello,I'am also dealing with the exact problem you are describing.My pmd is mounted on the intake,Good batteries,can here lift pump run,new fuel pump relay,no check engine light.no fuel leaks,new fuel & air filters,good glow plugs. It started stalling about 8 months ago.Its like you are turning off the switch.It will go weeks with out trouble then all the sudden it will stall for no reason.Start stall start 2 or 3 times in row then run like nothing happened.It might do it shortly after starting after its been sitting for a while or it will happen after running for hours.And then sometimes I'll drive for a mile,stop for 15 min.Then it won't start at all.Soon as I try to Trouble shoot the wiring or fuel flow it will start right up and run fine for days.I can,t find any loose damaged wires.But I Have'nt checked the other grounds. Buck


You might want to start a new thread and make sure to go through the check list (http://www.dieselplace.com/forum/showthread.php?t=42248) and post your results ... Alot of great people here and will help you as best they can ...

I called Heath Diesel yesterday, talked with Todd and got my harness ordered ... Shouldn't be long now ...

:mad: ... The mechanic just put the harness on and said the IP is bad ... http://www.truckingboards.com/trucking/upload/images/smilies/cuss.gif ... I just had a new IP installed ... I have suggested several times that if the harness did not fix the problem it most likely is the oil pressure switch ... Hopefully he won't have the truck torn apart before I get there tomorrow and I can get my Fin truck home so I can work on it ...

I bypassed the oil pressure switch and now it will run untill the fuel filter bowl is out of fuel and it dies ... Anyone have any ideas before I tow the stinking thing 100 miles to an experienced diesel tech? ...

I bypassed the oil pressure switch and now it will run untill the fuel filter bowl is out of fuel and it dies ... Anyone have any ideas before I tow the stinking thing 100 miles to an experienced diesel tech? ...
I am no certified mechanic but if you are running until the filter bowl is empty, this tells me you are not getting fuel from the tank fast enough. The "sock" in the tank might be plugged or your lift pump is not pumping. (running yes pumping no)
Just my thoughts.

I am no certified mechanic but if you are running until the filter bowl is empty, this tells me you are not getting fuel from the tank fast enough. The "sock" in the tank might be plugged or your lift pump is not pumping. (running yes pumping no)
Just my thoughts.


I'll have to check the lift pump (It was pumping when I went through the check list last), The sock is new, I have put less than 1,000 miles on it since I had the whole fuel system and tank flushed ...

Well, I think I have finally fixed my problem ... I replaced the PMD/FSD harness with the correct piece (The old harness was Jerry rigged and screwed up 2 PMD modules), Replaced the module with a new piece, And replaced the filter bowl since the old one had a hole in it ... The truck is running like a champ now ...

congrats...now go slap the mechanic that said IP...LOL