1994 6.5 died will not attempt to restart
 

1994 K3500 6.5 diesel Manual transmission
The truck died going down the road. Like you turned the key off. It has never made any attempt at restart. Unlike a PMD that will usually restart many times before it gives it up forever.

No smoke at the tail pipe

Grounds are double checked with an Ohm meter.
Checked fuses in the fuse panel on the dash. Have plenty of flow to the injection pump.
Have the lift pump hot wired have tried starting with the Crank position Sensor and the Optic sensor alternately unplugged.

I tried several different "known to be good PMD's and extension harnesses.

Fuel is good.

Changed the fuel filter even though it had plenty of flow to the IP. Filled the bowl with Sea Foam and ran it through the IP and out the IP return line - Not much flow.

It has just a dribble of flow out the IP return line with the lift pump running and the plunger removed from the Fuel Shut off Solenoid. When you crank the engine it sputters out the IP return line. I am guessing this is normal. Our 98 Suburban seemed to be the same til it was running and produced a stream of fuel out the IP return line

I got new batteries today. I knew that wasn't the issue but they dropped blow 12 volts when cranking. They were 6 years old and Farm & Fleet had them on sale for $79.99 84 month, 850 cca. I would rather have had the Sears Diehards with 930 CCA, but couldn't justify 3X the money.

I am not getting any fuel to the injectors.

I tried to start with the Crank position sensor unhooked

I checked the pins on the cable That comes from the engine and feeds the PMD
Pin A had 1.65 to 1.75 volts while cranking
Pin E had 0 volts
Pin C had continuity to ground - .02 ohms or so
Pins B & F had no continuity

Any ideas?

Do the accurate diesel no start guide for PMD diagnosis but I doubt it will help,the values you give mean little without the guide to go by.

Have you looked in teh oil fill to see if the IP is turning?
IP drive flange might still have a sheared key?

I haven't taken the fill neck off yet. I am as of now - til I get to taking the fill neck off assuming that it is turning.

It said on the diagnostics that Pin E should have 5.6 VDC with ignition on - I have zero VDC

B&F had no connectivity through the harness from the engine. If I understood correctly there should be .4 ohms between the 2 connections.

Would the lack of any voltage at pin E indicate anything?

Or pins B & F having no continuity between them? The tester stays on 1 as if you hadn't touched the pins at all.

Where do I find the info to tell me what the values i found might mean?

http://www.accuratediesel.com/nostart.html

OK pins b and F should have continutity because they are the electronic coil of the fuel solenoid,you might want to check those pins at the IP harness to eliminate any problems with the extension harness.

Likewise with pin e.

actually I am checking at the IP harness

I'll be glad when we get this truck running again. High of 15 and no heat in the shed. It's pretty hard to add heat without making some kind of enclosure to contain the heat. 16' sidewalls, 32x40. It'll be nice once it's insulated and I have a floor in it. Not so nice now. LOL

In that case there is a wiring problem or the fuel solenoid has an open circut and the IP needs rebuilt/replaced.

aNY IDEAS ON FURTHER TESTING and diagnosis to nail it down as far as what exactly is wrong

Remove the upper and lower intake,remove the boot on the fuel solenoid,remove the F and B wires from the solenoid and check continuity right from the solenoid terminals themselves.

If it's an open there you have your answer.

pins E & F have continuity and pin B has 5 volts with key on

A - Fuel Inject control - grn - to PCM

B - FSOL+ - lg red - to Fuel Solenoid

C - Closure ground - sm black - to PCM

D - +12v power - pink\blk - to ESO solenoid and IGN

E - Fuel inject signal - small red - to PCM

F - FSOL ground - lg black - to Fuel Solenoid and IP ground

FSD connections to 4-wire IP harness connector from PCM\IGN -

FSD A green to...........A IP connector

FSD C small black to....B IP conn

FSD D pink\black to.....C IP conn

FSD E small red to.......D IP conn

FSD B and F go to Fuel Solenoid on IP

Black ground wire attached to top of IP must be attached to top of IP

E and F should not have continuity,wires melted together?
C and F might have continuity since they are both ground but not sure?

I am looking at the connector that would go to the PMD.

The way I am looking at it - the pins would be - A E D C B F

Is this correct or am I chasing my tail big time. About to give up and look for a sghop that works on 6.5's First I would have to find one. LOL

http://www.justanswer.com/chevy/6wc6...t-changed.html

I will have to look at mine tomorrow,can't think off hand If I have seen a picture with the wire positions layed out?

Pretty much looking at the same info you have seen @ Diesel Place.

Yep you got it right acording to buddy's diagram.

It just doesn't make sense to me that I have 5 volts on B when I am supposed to have 5 volts on E and I have continuity F to E when I am supposed to have Continuity from F to B and do not.

It's like B and E are swapped, But how could that be possible? The truck ran great for years. Right up til it suddenly died.

The first time I never checked B for any thing but continuity to F the first time around, because it isn't supposed to have anything except when the engine is running.

If I thought swapping the IP would make this thing run, I'd be all over it.

But I can not afford to swap the IP and end up right where I am now.

Do you have any contact info for Buddy? I lost all the numbers out of my phone and can't seem to find his email

I usually just PM Buddy @ Diesl Place or TTS.

Got some good info today. The plugs are stamped as far as which wire is which.

I had a look at my spare extension harness and no markings as well as my spare IP today and didn't see any markings on it?

You should have 5 volts on E and you need continuity between B & F

There should not be continuity between F and E unless the wires are melted together,that could be very bad for the ECM.

I'm sure you've seen this already. I didn't notice any letters on any of my plugs either

By a previous post I did not understand that the pins were in alphabetical order across the plug. I also Could not see well enough to know the plugs were labeled with the pin configuration. Actually only about half the plugs I have are labeled.
Turned out I had a pin that was not making good connection. When I tested each pin they all read correctly. When I tested at the end of the extension harness I found an inconsistency.
It actually worked with a different harness that seemed to fit together tighter
When I have nicer weather, I need to replace the PMD/ injector pump harness.
Thank you much