I cannot affort to have this truck down. Please let me know what you think of the below. If it is time for a mechanic, any recommendations in the Syracuse, NY area would be appreciated. Either way, it will be sold in the near future, it's costing me more to be down than it is to fix.
1. Describe the problem you are having in detail: Two weeks ago, it died 1 mile from office, couldn’t keep it running. Towed home. New PMD on a heat sink on the manifold while awaiting the extension cable, drove 14 miles to work engine over-revs (redlines while in drive, accelerating), pull over, sits for a few minutes, restart finish drive (0.5 mile). Sits all day in the parking lot. Drive home, 11 miles, over-revs on highway, coast, restart results in over-rev. Allow to cool 2 hours, drive 3 miles, over-revs. Allow to sit overnight, drive the rest of the way home. Clean the engine bay with Purple Power and water, pull, clean and re-tighten positive cables and grounds. Install new PMD 3/21, relocated to the hole in front bumper. Drive ~8 miles up two large hills, reaches operating temp, no issues. This morning, drive ~1.5 miles from home, stalls like two weeks ago. Wait 3 minutes, start and drive home. Park truck.

2. Year of truck (http://www.dieselplace.com/forum/showthread.php?t=42248)/engine. [/FONT][/COLOR]1999 Suburban 4x4/6.5 TD
3. Odometer reading (indicate miles or kilometers). 163,132
4. Indicate the model number on the Injection pump (starts DS4 or DB2......). Unknown
5. Indicate if you know if it’s a 1500, 2500, 2500HD, 3500, 3500HD. 1500
6. Do you have an EGR on the engine? (An F or an S engine code 8th VIN digit) Don’t know
7. Air Filter condition (visual check). New
8. Fuel filter condition (freshly changed, mileage (http://www.dieselplace.com/forum/showthread.php?t=42248) since changed). 10 miles
9. Location of PMD/FSD (http://www.dieselplace.com/forum/showthread.php?t=39436)? (ex. on pump/remote over intake, behind bumper). “booger” in bumper opening
9a. If remote mounted, describe wiring harness (homemade or purchased from which vendor). Purchased from Accurate Diesel – Installed 3/21.
9b. Indicate the location and condition of the FSD/IP grounding wire. On IP
10. Outside Temperature (C or F). _____ ° 39 F (60 F last two weeks)

11. Service Engine Light while running?- on/off/intermittent Off
11a. Service Engine light does glow during start/cranking/bulb check: Yes/No Yes
12.Have you scanned for engine codes? Yes/No No - haven't been able to keep it running to get to AutoZone
12a. List exact results on engine codes (http://www.dieselplace.com/forum/dtc.php).

13. Condition of Battery terminals removed, cleaned and tightened– yesterday – 3/21.
14. Known condition and age of Batteries. Good, 1.25 year old Interstates
14a. Are batteries a matched set of same age? Yes
15. Condition of Major Grounds (http://www.dieselplace.com/forum/showthread.php?t=157085) removed, cleaned and tightened– 3/21

16. Does engine crank, or "turn over"? Yes
16a. Does engine start and run? Sometimes
17. If engine does not start- Crack injector line (http://www.dieselplace.com/forum/showthread.php?p=2188140#post2188140): do you have fuel (http://www.dieselplace.com/forum/showthread.php?t=42248)? Yes/No Yes
18. Does your Wait To Start light come on? Yes
18a.Number of seconds WTS light is lit. 1-2
19. Engine Cranking speed (if you have an accurate tachometer). Unknown

20. Are you experiencing Stalling? Yes
20a. Describe the event (upon startup only, down the road, hit a bump, etc...) Two weeks ago cold, today - cold
20b. Do you notice loss of dash or instruments? Only speedo and tach
21. Check turbo inlet and air filter for obstructions. Yes
22. In a no-hot start, pour a bottle of room-temp water on the injection pump. Does it start now?
23. Lift pump test (http://dieselplace.com/forum/showthread.php?t=39350) - Describe results. Passed – lift pump 1.5 years old.

24. Upon cold start, does the radiator hose get hard quickly? Yes/No Unknown
25. Upon cold start, do you have excessive white smoke? Yes/No White smoke at start, it’s a diesel so not sure what excessive is. Small cloud about the length of the truck.
26. Do you have excessive cranking time before the engine starts? Yes/No No
27. Have you used the block heater? Does it affect engine starting? (only try for starting problems). Yes, Helps when it’s below 0 F
28. Are all glow plugs in proper working order (http://www.dieselplace.com/forum/showthread.php?t=39182)? Unknown

29. During hard acceleration, do you have excessive black smoke? Yes/No Don’t accelerate hard, I drive like a Grandma
30. Do you have any unusual exhaust smoke issues? Black smoke when it what over-revving when hot.
31. Turbo check out (http://dieselplace.com/forum/showthread.php?t=39368) - Pass/Fail Unknown
32. Indicate fuel that you are using: Bio-Diesel, #2 Diesel, SVO/WVO, other #2 Diesel
32a. If running Veggie Oil fuel setup, indicate details of your conversion (homemade or packaged system). N/A
33. Are you using any fuel additives? If so, please list. Power Service Diesel Fuel Supplement +Cetane boost (white bottle) and 2 cycle oil.
34. Upon unscrewing fuel cap, do you have a large vacuum formed in the tank? Yes/No Sometimes
35. Do you have any service history available that might pertain to the problem you are having? IP less than 2 years old, PMD brand new, lift pump 1.5 years old, Service records from original owner and my own.
[COLOR=black][FONT=Verdana]36. Please indicate any modifications to the vehicle that might help us diagnose better. To my knowledge, truck is bone stock

did you test see if OPS and LP working

LP yes, OPS no. Oil gage on dash reading 40 at idle, 60 under load just after start up.

OPS should not matter in controlling the LP in a 99. It is only on 94-95.

IIRC, we agreed in the other thread you created that the IP may be going south. But we will not know until we can read the codes to make sure that they are IP codes.

Just to make sure, you may ask by PM to a member called DieselPro. He is the resident IP expert here.

Would this just be the standard OBDII code reader to get the codes? If so, I'll pick one up to read them.

In the other thread, 2 different people said they had an over-rev problem that was solved by the PMD, so had a replacement sent to see if it was the PMD.

Strange that of the three different PMDs, two stall and one rev's.

Thanks for the response, may PM the member you mentioned.

PMD may solve. Keyword is "may", it has happened before but if it keeps happening, then the IP components may be bad. I could be wrong. May be mods can help you. I know DieselPro certainly can give suggestion.

are these "new" pmd's or new used ones?

Purchased from AccurateDiesel.com - they are new PMD's.

Believe you have the broke armature syndrome. IP will need to be replaced.

Search armature > Quantum mechanic

Thanks DieselPro, that's what I was afraid of. Anyone know (ballpark) what to expect to pay to have an independent mechanic replace one?

It's going to get fixed and then sold. If someone wants to work a deal on the truck as it sits, please let me know via PM.

Thanks.

Ken

Guys -

Thanks for all of your help. One final question:

When an engine throws the codes, does the check engine or SES light always go on? I've never had either of them light up, other than start up.