Hi Folks,

Newby here. I found the excellent help guide and check list on this forum and wanted to check in with the experts to see if I could get some thoughts on my strange no start problems.

I have completed the checklist below, but wanted to add some detail prior to having folks read the checklist in light of comments made by Turbine Doc regarding IP issues.

Everything seems to point to a new IP needed, but the symptoms, no start, hard start, runs OK, and then back to no start seem to indicate something else (well, that is what Turbine Doc seems to indicate!)

Any thoughts on what I can check next to see what the problem might be?

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BACKGROUND:
135k miles. Running fine until a few weeks ago. Stopped for no reason, suspected gas contamination (still not sure if it was). Fuel emptied and fresh diesel filled. Was very hard to start but once started (I assumed air in the line after reconnecting the lift pump), ran fine for a week . A week ago, no start, and after extended cranking, started and ran fine for a day. Next day, with battery booster attached - so high crank revs - she would occasionally start, and then die after 30 secs. Now, no start with or without booster ...

THE FOLLOWING IS NOT IN THE CHECKLIST

Fuel shut off solenoid - piston removed yesterday (appeared functioning prior to removal) - Solenoid refitted and torqued down. No leaks, O ring in good shape. #1 injector removed and engine cranked for 3 minutes in 30 second crank/5 minute wait to clear air from IP.
No flow at #1 or #3 injectors during the above, or since.

Current PMD key-on tests:
A to ground = 1.2v
D to DVM to ground = 12v
C to batt DVM to ground = 12v
B & F = 0.6-0.9 VAC cranking.

Good spare PMD substituted, same readings from replacement

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DB CHECKLIST

Problem: Explain your problem in concise language (ie: Cranks but won’t fire). CRANKS NO START

Demographics: tell us about your truck and your ambient conditions:

- Year: 1997
- Truck model and class (ie: c2500) C2500
- Automatic or Standard AUTO
- Mileage: (indicate miles or km) 135k
- Replaced parts and mods (IP, PMD, chip/PCM, TM, injectors etc) PCM
- Model: ‘S’ or ‘F’ engine, NA or Turbo, EGR? TURBO+EGR
- Ambient outside temp: (indicate *C or *F) 80degF
- What fuel are you using? (#1 Diesel, #2 Diesel, Bio, VO, WVO, etc) DIESEL
- What fuel additives are you using? ___________
- Where are you located? NORTH CAROLINA
General maintenance: inspect and evaluate the condition of each. When were they last changed?
- Air filter JUST CHANGED
- Fuel filter JUST CHANGED
- CDR Valve? _________
- Coolant – last flushed/replaced at _____________
- Oil – synthetic/regular, SYNTHETIC CHANGED 134K
- Batteries – state of charge, (matched set) replaced at NEW 11/2015
- Battery cables and grounds (removed, cleaned and tightened): _YES
- Glow Plugs - how many miles on them? 135k What type? _____________
- Injectors - last changed at _______________


History: (Describe how the problem first appeared.) SEE ABOVE
- What were you doing when it happened? ______________
- How was the truck running fine before this problem appeared? _____________
- Has this problem ever happened before? _______________________
- Describe any related factors that might be part of the problem. ______________
- Have you checked for DTC (Diagnostic Trouble Codes)? (Y.N) Y And? P-1218 (RESISTOR MISSING FOR LAST THREE YEARS. No CEL)


Diagnostics:

1] Starting:
1a] Does the engine start? NO
1b] Does the engine crank over? YES
1c] Are your batteries fully charged? YES
1d] Have you removed, cleaned, and tightened all battery connections? YES
1e] Does your Wait to Start light come on for a time? How long? 30 SECS
1f] Does your glow plug light come on? _________ For how long? _________
1g] Do you see smoke from the exhaust while cranking? What color? NO

2] Fuel Issues (if not running):
2a] Can you hear your lift pump working? YES
2b] Do you get a steady flow of fuel from the water drain (T-handle) ? YES
FUEL RETURN LINE CHECKED. FUEL FLOWING FREELY INTO CATCH CAN WHEN CRANKING.
2c] Loosen the inlet line from the IP – is fuel coming out (Lift Pump on)? ___________
2d] Loosen an injector line and crank the engine - does fuel come out? NO
2e] Do you hear a vacuum (hiss) when you remove the fuel cap? NO

3] PMD / IP Issues
3a] Location of PMD (on pump, on intake, remote mounted) REMOTE ON HEAT SINK
3b] Condition of Extension harness (if used) Vendor or Homemade? VENDOR
3c] Condition of grounds / ground wires to IP / PMD. Check Harness. GOOD
3d] PMD Make: ___________
3e] PMD Age: 2YRS AND 3YRS

4] Stalling Issues – NONE EXPERIENCED
4a] Do you experience stalling only when hot?
4b] Does it stall under particular circumstances? (ie hit bump, or on accel)
4c] Does pouring cool water over the IP seem to help with restarting? _________
4d] Is stalling momentary (engine recovers)? _________
4e] Does SES light come on when engine hiccups? _________
4f] Does cruise control quit working when engine hiccups? ___________
4g] Does re-starting seem to reset engine, restoring cruise and power? _________
4h] Changes to dash lights or instruments during stalling events? ___________

5] Running Issues NONE APPLICABLE
5a] On cold start, does upper rad hose get hard before engine warms up? _______
5b] Any bubbles or oil film in coolant overflow tank? _______
5c] Any white slime on oil surfaces (dipstick, CDR, oil Fill cap)? __________
5d] Excessive white smoke from exhaust on cold start? _________
5e] Excessive black smoke from exhaust under hard acceleration? __________

6] Performance Issues NONE APPLICABLE
6a] Do you have gauges? ___________
6b] Maximum boost under load? ____________
6c] Have you added a performance PCM (reflash) or Chip? ______________
6d] Have you changed exhaust / downpipe / crossover? ________________
6e] Wastegate – mechanical or vacuum? ______________
7] Temperature-related Issues:
7a] Single or dual thermostats? ____________
7b] Have you replaced them lately? Manufacturer of replacements? _________
7c] Have you pulled and cleaned Radiator and coolers lately? ____________
7d] Have you replaced the fan clutch? Manufacturer of replacement? ________
7e] (winter) Have you tested your antifreeze? Good to what temp? __________
7f] (winter) Are you using a winter grille cover? ___________

 

Take supply line off at pump make sure you are getting fuel to injection pump . I have never trusted checking return flow . 6.5 and 6.2 can pull some fuel from tank on there own even when lift pump is bad .
If you have fuel and no start . Hook line back up . Un hook glow plugs . While cranking give a short blast of starting fluid (Remer to unhook glow plugs first and remember I said short blast ) if engine fires and dies you can be sure you injection pump had issues .
PS . I very much dislike starting fluid but used for test purposes it is ok . As long as glow plugs are un hooked