GM-GMC: 1996 GMC 3/4 ton Sierra, 6.5 l diesel, fuel injection pump, gmc dealers


Question
Two months ago my 1996 GMC 3/4 ton Sierra, with a 6.5 L diesel, started to cut out all of a sudden.  What I mean by cut out, is that it could be idling or going down the highway and it will shut off.  At first I thought it was a fuel problem.  But now I think it is more electrical.  Once it has cut out/shut off I can easily restart it and it will run fine until it shuts off again.  This seems to happen more in the morning when it is cold, but it will do it anytime.  Once it has done it 3 or 4 times it will run fine for the rest of the day.  I have had it at two GMC dealers and they do not seem to have an idea of what the problem can be.

Answer
Although I do not own a computer-controlled diesel, I have read enough on forums to be able to provide some suggestions:

1) Remove and clean all battery connections, both ground and positive wires.  The computer-controlled diesels are very sensitive to poor grounds/connections.

2) The Pump Mounted Driver (PMD), which is the black box mounted to the side of the fuel injection pump is prone to heat-related failure.  It does not cause any OBD diagnostic codes to be set that can be read with a scanner.  The cure is to buy another PMD and remote mount it away from the injection pump and, if possible, off the engine.  Aftermarket kits are sold for this purpose.

3) The injection pump uses an optical sensor which can also fail.  Usually, a diagnostic code is reported by the computer.  Repair usually consists of replacing the injection pump.

There is an extended warranty by GM for these problems.  I believe that it runs 10 years or 120,000 miles and is honored for any owner of the vehicle.  Check with GM about this.