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?