You'll be limited with the OBS tuning unless you get a custom tune to what mods you decide to do.
IMO I would do gauges (boost/EGT/trans) first, then add a 4" cat back exhaust (diamond eye w or w/o muffler) and a hydra chip with the tuning of your choice (totaldieselperformance).
After doing...
Do you know the condition of the glow plugs?
If not, you should pull them and inspect (or replace for under $100).
I've seen glow plugs test "good" with a meter, but when 12v is applied they hardly glow at all.
Is your block heater working? Have you tried plugging the truck in for at least 3...
good point about the clutch fork. Known issue with cracking. The OP could remove the slave cylinder and measure the distance from the bellhousing opening to the fork. I'll have to look around for the correct distance on a working fork.
If you're certain it's at the bottom of the pan, it *probably* won't hurt anything. I state "probably" because although the pan is deep, there's still a round metal disc where it doesn't belong. I would most worry about it getting sucked up against the oil pickup tube.
You could try going in...
remove both valve covers
with the engine running look for equal amounts of oil coming from the spouts on each injector indicating they are all firing the same.
there should be no oil leaking from the top part of the injector
to disable an injector, unplug the two wire plug going to the...
That's your problem. Fuel pressure should be almost "instant" when cranking with a correctly working mechanical fuel pump and regulator.
How old is the mechanical pump? Has the regulator on the fuel bowl ever been rebuilt?
Personally I prefer the mechanical pump on the OBS compared to the...
If it started the same with the auto PCM that is a fair enough test to confirm your PCM is not bad. The truck probably threw a bunch of codes for the missing auto transmission sensors.
I'm confused now. Earlier you said it started have problems after installing a chip? Now you've gone through...
Can you post a video of the problem?
If it's the dual mass flywheel and it fails catastrophically it can take out the bellhousing or crack the transmission case.
I still think it's something to do with the chip, since you said the problem happened immediately after installing it. Can you get another unmolested PCM to borrow and swap in?
Also the IPR could be the issue. Just because the PCM is asking for a certain duty cycle, doesn't mean the IPR is...
Could be IPR solenoid getting hot and quitting.
Could be o-rings leaking when "hot"
Can you monitor the truck and log what's going on when it stalls out ?
Do you know the service history of the glow plugs and relay? If not I would replace all 8 glow plugs with OEM and upgrade the relay to the larger stancor unit.
The power cord goes to a block element near the oil filter. The cord can be purchased new or the old one can be repaired.
If you're glow plug system is working correctly, there really isn't any need to "plug the truck in" to warm the block. I've started at -20F with only glow plugs.
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