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OT but need help on 6.5 turbo long post

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huntingreen

10-25-2007 06:20:31

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This is an off topic post and a long one but I would appreciate any help I can get. I have a 96 Chevy truck with the 6.5 turbo engine. In late Sept. I started to a tractor show. While sitting in my drive I noticed the engine stutter a couple times. I headed out down the road and it stopped after traveling about 2.5 miles. I was able to restart the truck and drive for another � mile before it stopped again. I managed to drive it approximately 6 miles so I could hook up with a buddy and catch a ride. After we returned from the show I started home in my truck. It died after going about 2 miles. After sitting about an hour I was able to restart it to complete putting it on a trailer to haul it home. Got home and drove it off the trailer. Managed to get it in the shop. It was an off again on again thing getting it to run. So I ordered a replacement PMD and a heat sink. I have the book from Diesel Engine.com. I have cleaned the battery cables. Checked the fuel pressure, 6 PSI cranking, Pulled out the fuel shut off valve and it appears to be working. Pumped fuel into a clear bottle and it appears to be ok. When I turn the switch on and pump fuel into a clear bottle I will get a couple cups full and it shuts off. I take this to be the oil pressure switch doing it thing since the engine did not build up any oil pressure. I have run jumper cables from the ground to the engine. Installed the replacement PMD (used checked out bought on ebay) and the engine started right up. Drove it about 20 miles and parked it. Thought everything was fine. Next time I went to use the truck the problem started again after about 5 minutes of running. So back into the shop and continue with investigation. I thought I found the problem in a short wiring harness that connects to the top of the injector pump. So I ordered that. Installed it last night. Started engine up and it ran about 5 minutes then died. It would restart again about 5 times running less each time until it got to the point it would not start again. When it starts and runs it runs great until it dies. No white smoke, no excessive black smoke. Only black smoke when you have it loaded or getting down on it. Truck has 146k miles on it. Fuel pump was replaced in the last 2 years. Fuel shut off switch was replaced in the last 2 years. We had a stall problem about 2 years ago and managed to fix it by tightening up the wiring connections on the wiring harness I just replaced. Any help would be appreciated.

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Randy S

10-25-2007 16:48:09

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Re: OT but need help on 6.5 turbo long post in reply to huntingreen, 10-25-2007 06:20:31

I have a 94 6.5 turbo and 6 lbs. fuel pressure from the lift pump isnt enough. Mine runs rough if at all with only 6 lbs. The lift pump is only good for a couple of years at most, I wind up changing mine about every 1 1/2 years.

Is the pdm the same as the driver box on the injection pump. If so it can also go bad and never would i change it with one from ebay. There is also a very tiny curcit board on your original driver box that must stay with the original engine. Its on the pins where the electric plug connects to the box. I use a paper clip to pull it out and install it on the replacement box.

Good luck
Randy

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ejr-IA

10-25-2007 13:32:32

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Re: OT but need help on 6.5 turbo long post in reply to huntingreen, 10-25-2007 06:20:31

Pluged filter

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Jim K

10-25-2007 12:51:16

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Re: OT but need help on 6.5 turbo long post in reply to huntingreen, 10-25-2007 06:20:31

Check the wiring circuit for the fuel pump and I mean every connection for continuity. then get a 12 volt test light and turn on the key and follow the circuit and test for power throughout it's entire length, did I mention to get a wiring diagram. Makes things alot easier. No guess work. you either have power or you don't.
The symptoms you describe, it sounds to me like a connection is loose and as it heats up things expand and you lose connection. check the fuel pump crash sensor and the connections there.
But I am willing to bet the fuel pump power circuit is the culprit.

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Kevin (FL)

10-25-2007 10:41:07

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Re: OT but need help on 6.5 turbo long post in reply to huntingreen, 10-25-2007 06:20:31

I'm not clear about what you said about the oil pressure switch, but if you can get it running, can you confirm that the lift pump is running while the engine is running? Also, I didn't see where you bled the fuel filter. Don't crack the vent though until after you confirm the lift pump is running while the engine is running--otherwise you'll get more air into the system.

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Bob

10-25-2007 06:49:14

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Re: OT but need help on 6.5 turbo long post in reply to huntingreen, 10-25-2007 06:20:31

What trouble codes is it throwing?

It could be a lift pump or air leak into the fuel system (DESPITE the fact you assert the lift pump is good).

It could be a bad crankshaft position sensor, or perhaps a bad "optical encoder" in the pump, where you wiggled the wires.

The "tested" PMD could be intermittant, or the fuel solenoid could be going south. (The one that is required to pulse for EACH injection event.)

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