1994 6.5L Turbo Diesel w/EGR Engine Cranks - No Start
 

Hey everyone,

Thanks in advance for reading my saga.

I picked up this truck two years ago from a friend who had gotten it running previously. She's been fairly reliable. About two months ago I decided to do the ball joints on the passenger side. I also took it to a shop to have the pitman arm replaced. When it went to the shop, the transmission failed. No, I will never take it to these guys again.

Late December I had the transmission replaced at a local guy who has a great reputation. When I picked it up, she never ran better. The total drive home was about 30 miles.

In the last few miles before arriving home, the engine died. Normally I could to a "hot restart" while driving in neutral when this happens. But now it just cranked with no catch.

What has been done to date:

1. PMD was replaced in August 2019 and relocated from the brake master cylinder area to the front bumper. I've swapped in the old PMD which was intermittently failing before. No Start.
2. Replaced the MAP sensor which was causing a DTC31 and DTC57. Still No Start.
3. I went through the steps outlined here: https://www.accuratediesel.com/nostart.html and replaced the Crank Position Sensor. No Start.
4. Checked all of the voltages at the EGR relays, boost relays, etc. We did this because the truck is throwing a DTC62. No issues were found here.
5. Completely reworked the grounds at the back of the motor and front of the motor. New eyelet connectors and the works, Checked resistance to ground. No issues. No start.
6. Checked the fuel return from the Injection Pump, there is fuel return. But I have a question about the pressure.. Should it be a squirt or dribble? Blew into the return line and can easily blow back to the tank.
7. Replaced the fuel filter. Bled system out by activating the lift pump at the ALDL connector. The pressure seems good, I know this because I forgot the O Ring on the new fuel filter and created a sprayed mess.
8. Checked all fuses related to fuel, including the hot block under the cover in the engine bay. No issues found and 12v is present.

What is left? What am I missing?

Thanks in Advance!

Side note: Is there an electrical test that can be done on the PMD for diagnosis?

Update:

Ordered another PMD off of eBay.. Son of a bitch, my brand new PMD is dead!

New issue: Truck starts, but idles "low" and rough. No response from the accelerator pedal (no revving)