Well, I pretty much wrapped up the cooling mod project tonite - so to speak. Got everything back together with the exception of the upper and lower fan shrouds. Left them off until I can verify that I have no leaks on the low side. I plan on providing some words of wisdom on this project when I trulely have it wrapped up. Read on.

While I had things apart, I remoted my PMD and cooler to the front of the truck - between the driver's side battery and headlight. I'd previously had it mounted off the intake. In the process of fabbing a bracket to mount the FSD cooler to, I knocked the unit off the bench :eek:. Finished mounting the bracket and cooler and reinstalled the battery.

Jumped in the truck and went to fire it up. As per usual and after the batteries are disconnected, I had to turn the key to the run position several times before I got a full glow cycle - for some reason the relay kicks out almost immediately. Tried to start the truck - nothing. Turns over a mile a minute, but no fire. Now keep in mind, I drove the truck in - it was running like a champ. Now no fire. Could dropping the PMD and cooler have damaged it? I took the connection apart, reseated it and still no fire.

How well does the PMD and cooler have to be grounded when remoted up front such as I have? Don't have a spare PMD that I can try, and it's VERY unlikely that I can get my hands in to reconnect the PMD stil mounted on the pump. If you thought it was difficult with the single cross-over manifold, it's even worse with the dual. I had a Censored of a time trying to get the connector off the pump mounted PMD and free it from its confines.

Any and all help/ideas would be greatly appreciated.

My PMD isn't grounded in the air filter box. . . I guess I better not say anything to it, or it may demand it's ground. J/K.

Anyway, did you mash over the wire to the fuel shut off or something on top of the IP? Got fuel to injectors?

Mash over the wire to the fuel shot off ? Not sure I understand. What wire would that be?

Haven't checked fuel to injectors. Figured I'd start this AM by checking fuel at filter, etc. Maybe move the PMD back to the intake and see if that helps. It is one of the things that 'changed'. (In my line of work, we always ask 'what changed' when something goes wrong, so it's a habit to take a step backwards when troubleshooting.)

Silver clyinder on top of the IP.

Check the injectors, no fuely, no runny.

Make sure the PMD is securly grounded on top of the IP via the remote harness (hint* ground wires are black). The truck won't start without it.

Well, I've narrowed it down to either the PMD or the harness. Just got back from a trip into one of the diesel service places in Milwaukee where I picked up a used PMD - call it a glove box spare. Plugged the used PMD directly into the original connector and bingo, we have ignition, contact and start. Truck is running as we speak. Hoping to get it up to normal operating temp so I can check for leaks and put the shrouds on.

In a minute I'm going back out to check for leaks. Barring and problems there, my plan is to connect the used PMD to the extension harness and see if the truck starts/runs. If it does, then I'll connect the now remoted PMD directly to the original harness and see what gives. Simple process of elimination - one thing at a time, working from known good/functioning components.

Thru a process of elimination, I found that the cooler extension harness was bad. Both PMDs work fine when connected directly to the original connector. For now I have the cooler and PMD back off the intake. The used PMD I got earlier in the day will go in the glove box. Gonnea have to check with JK and see what I can do about getting a replacement harness when he gets back from Montana.

If your glow plug relay is kicking off immediately, then check your grounds for your batteries. This has happened to me on several occasions after disconnecting the batteries and later reconnecting them. If I don't have them tight enough, the relay kicks off right away and the engine won't start, since the glow plugs didn't make a fire inside.

I'd start there because it's free of charge if it fixed your trouble.

SnowDrift