Hey Yall! Just registered with the forum. I have used it as an invaluable resource with my project 6.5 that i have had for about 6 months (3rd owner). I just fully rebuilt my 6.5 with 158,000 miles. Bored the cylinders 0.030" over, new main/connecting rod bearings, full sealed pro gasket kit, fel-pro head bolts, new ac delco harmonic balancer and main pulley, new bosch injectors pop tested to 150 bar, new diesel Rx glow plugs and controller, new heads (both sides), Relocated PMD to bumper (Pensacola Diesel kit), and I'm sure there are a few things I've forgotten.

The problem... Got the oil primed to the turbo line with the glow plugs out. Kept turning it over to bleed injector lines and got no fuel at injectors. Read threads on forums about the importance of clean grounds. Went through them and my green lead at the PMD started to read good voltage and within 3 crank/rests there was fuel at the injectors. Tightened them attached the exhaust and the second crank it fired, ran for a couple seconds and cut out. The next crank it fired up idled a bit high and was chugging a bit, i thought it was the injectors priming. It started to sound like it was going to level out and died. No restart. Took battery cables off for 20mins. No restart.

This is what leads me to you fine gentlemen for assistance. Another peculiar thing about the truck is that i have never seen the Service Engine Soon Illuminate, not even in initial start up. Also just before i decided to pull the engine and rebuild it the Glow Plug light stopped coming on, which I thought was the relay but same symptom after replacement.

I am thinking ECM? I can get a reman delco from Rock Auto for $120. Also Fuses under hood ECM B-always hot, ECM I and ENG I 0.10 below ECMB fuse, and glow plug fuse will give me a suge of current when the key is first turned to on

Any help you can send my way will be greatly appreciated

Thanks
Chris

 

Make sure the LP is operating when the engine runs-OPS controls power to LP at that time and is a common failure item-AC Delco ONLY for OPS and google OPS relay mod and install.

Check the bulbs for wait to start and SES-might be burned out?

Use a code checker to see if ECM is communicating since the SES light is inoperative and you can't check codes with a paperclip.

I know you already have them but diesel RX are not that great a glow plug-Bosch Duratherm's are the preferred glow plug for future reference.

 

Thank You for your response. The lift pump runs strong. You can hear it rattling as soon as you turn the key and all the time till you turn it off. Have fuel to the filter and the drain T.
Actually made some headway today. Pulled the gauges and saw that the SES light was absent! The guy i bought the truck off of must have pulled it so he could tell me there wasn't a persistent check engine light. Also the glow plug light was burnt out. I switched a couple bulbs to the SES and GP positions and they lit right up. Knowing this I bridged the terminals in my OBD1 connector and can now read codes. I get a DTC 31 - EGR Control Pressure/Baro Sensor Circuit Low (High Vacuum). A DTC 49 - Service Throttle Soon Lamp Circuit Fault (which I'm not worried about because i used that bulb for the SES) And a DTC 57 - PCM 5 Volt Shorted. This one is troubling me because i have spent 2 days cleaning and reattaching grounds. They all ohm out with a Craftsman multimeter.

I know I stated previously... but the main problem I have is very low voltage at the green wire on the PMD, only about 0.5v. When the truck did run briefly i had 1.6v and fuel to the injectors. Now back to low voltage and no fuel.

Thinking its the ECM itself maybe was on its way out before I pulled everything and just won't sync up now. Any other theory's are welcome. Old girl has been on jack stands for 2 months now.

 

It sounds as though your lift pump has been changed to run at key on.

Try a known to be good PMD and extension cable. I would not buy anything from Pensacola.

Or put yours on another 6. and make sure they are functioning. New means nothing, they have to be known to be good.

Find the PMD checklist. I may have posted it here. You are never done with diagnostics til you have completed the PMD diganostics

 

The voltage problem on the PMD/IP harness along with the code could indicate a PCM problem or a mouse has chewed through the harness under the intake somewhere?

 

Tdc relearn done?

 

Took racer55's advise and pulled the intake and went Ohm crazy with the meter. All the wires in question had good conductivity all the way through the harness and all others looked solid. Turned out to be a fools errand, put it all back together and the same thing no start and Code 57.

I have not done a TDC relearn. I don't have a scanner and the truck hasn't run more than a few minutes at a time to be able to take it anywhere. I did buy a Reman Delco PCM should be here on Saturday. I will keep you posted on the progress.

 

Well got my new PCM today and everything is so much worse! Glow plug controller will only initialize for 2 seconds. Only 0.15 volts to the Green PMD wire. And now the SES light flashes codes at me even without a jumper wire hooked up. I even put the old PCM back in and had the same result. I also installed a new OPS.

So confused. If anyone has any ideas I'm all ears.

 

Short glow cycle is normal when batteries have been disconnected.

Did you transfer the prom/chip from the old ECM to the new 1?

 

I did disconnect the batteries for a couple hours today. Took them to Advanced to be tested because of the symptoms. Their test came back good battery. I did transfer the prom.