Rich, this afternoon I had to take a 100 mile round trip for work, and the truck acted up the entire way, stopped at the shop to turn in paperwork, and the truck was fine all the way home, although it seemed a little underpowered. The new ICP is a Delphi from Napa, if that happens to be a troubled one, but I think they are the OEM manufacturers.
Larry, that is a great post! I am busy through Saturday but I can do as described on Sunday and get back with what I can find. I'm hesitant to buy another ICP, but I know where there is another that I can borrow that doesn't have this issue.

 

Gengine, often times it is not the actual content of a post that gets you thinking but the process of reading and doing the actual tests. That then spurs you to think of something else. In your situation, which is so much like many others here who are frustrated by lack of progress, it is important to "re-stir the pot". Even if it turns out to be something else than what is discussed, many of the ideas brought up here can help someone else. Corrosion in high salt environments; excessive current flow causing heat related carbonizing of relay contacts which can then intermittently fail much later, etc. Even mating wire connections can be damaged by too much current flow which equals heat. Carbon is a poor conductor.
Larry

 

Well, I didn't mess with anything last night, as I had firewood to put up and a bed calling my name, but the truck never cut out today…although it seemed to almost flood when I accelerated. Even had a little black smoke to go with it. I checked the turbo the other night when I was messing with all the elec. on top of the motor while I had the hoses off for accessibility, and the turbo felt fine to me. Not enough side to side to rub on the housing, and no in and out movement. It spun freely without the feeling of it catching. Air filter is only a couple hundred miles, and surprisingly clean. So possibly related to the injector issue, but is there something that would make my truck over fuel almost like it was flooding? How does the truck know how much fuel it needs? So what I am thinking is possibly something like a mass air flow sensor going bad...

 

anyone close by you that you could borrow a pcm from?
an auto trans pcm will run your truck.

 

My FIL happens to have an early '99 auto as a parts rig…if an auto trans pcm will work, i'll try it.

 

I was under the impression that auto and std pcm's are different. A pcm substitution from a willing donor is a good idea! There are just so darn many things it could be.
Larry

 

Regarding the PCM swap I'll paste a quote from Cody that I found in the cyberwebs:

"One difference is the PCM's acceptance of the long-lead injector. Early 99's didn't have it. The DAC3 would be in a truck that was equipped with a LL #8 injector. Besides, in the E99 box, the fueling and <acronym title="Injection Control Pressure">ICP</acronym> tables are set up for AB injectors and 15 deg. <acronym title="High Pressure Oil Pump">HPOP</acronym>. The DAC3 will be setup for AD injectors and a 17 deg. <acronym title="High Pressure Oil Pump">HPOP</acronym>."

So I'd think the e99 PCM is not gonna work so well, and maybe not at all. But it's easy and free so worth a go IMO.

But on a more positive note; I've been chasing a similar issue and tried many of the same fixes. Nothing was working and my AE is having connection issues. I had a long conversaton with my life coach Jim Beam, and he suggested I slap in a reman IDM. That did not work, but his ideas rarely do. Today I went back to basics and slapped in some new fuses at locations 12, 22, 23, 36. OE (pictured) was "good" but the tarnish on them was ugly. I replaced with new. They also had tarnish but some emory cloth fixed that. Gave the truck a good 15 minute run at approx 2k rpm, no problems. No chance to give it a real road test yet but so far, so good. My suggestion is swap in some new fuses at those locations.


Edit: Dawned on me your 2000 has different fuses than my 2002. Looking at the 2000 owners manual (pdf below) I'd replace 15,19,30 in the cab and 7,19,24,27 under the hood. Also under the hood swap relays 30 and 32 if they are the same.

 

Well, I got swamped this weekend and didn't get anything done with the truck. However, everything was running fine Thursday afternoon, and didn't act up Friday either. The truck sat Saturday and Sunday, I replaced the PCM relay with my brand new spare I carry, (Thank you Larry and David), and the truck hasn't acted up in around 350mi. So, I don't know if I wiggled the right wire or replaced the relay and that solved everything. Either way, the truck has been fine for the last four days, but I am still getting that great fuel mileage…189mi today on 9.2 gallons. 20.5mpg isn't a symptom, is it? Anyway, I want to thank you all for all your help with this, and I will post back if my problems come back, as well as the results of the tests that I have yet to try that were posted here.

 

We'll keep our fingers crossed for you. Time will tell in this case.
Larry

 

Good to hear it is working for you so far!

I also put in new BWD relays at the PCM and IDM locations, and the symptoms in my truck are much better. Not sure if it was the new relays or the new fuses just before... A glitch or two this week but completely driveable, back in service as the commute ride. I think your issue and mine are similar. The new relays may just be replacing tired ones, and the cause will work it's slow voodooo on the new relays until they also fail. But we'll see. Please post up at the first hiccup.