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1999 Chevy 3500 6.5 TD won't start

B

BZ52972

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I just recently bought a 1999 Chevy 3500 with a 6.5 TD(my first diesel). It ran pefectly for the first couple of weeks but started having trouble with starting. As of right now, it will start and run for about 15 seconds then die. Will start again a second time and then die again and then it will not start again for an hour or two.

Problem seemed to coincide with my son purchasing some fuel that had water in it. The water in fuel light came on and we followed the directions for draining and light has not come back on but truck got gradually worse about starting. I have checked the GP on the driver side and all read about 1.5-2.0 ohms. I could not access the passenger side before it got dark. When I go to start it and turn the switch the WTS comes on for about 30 seconds and then goes out. I can start it and the WTS will flash a few times and it will run for about 30 seconds then shut off. I can start again and same thing but after the second start it will not start again for an hour or so. The truck was purchased from a local dealer and was owned by the dealerships owners race team. It appeared to be very well maintained and is very clean under the hoodand like I said ran perfect for about 2 weeks.

Any help will be greatly appreciated.
 
I would check the lift pump and also try a spare pmd. Also sounds like you could have got some really cruddy fuel that might have plugged up the sock in the tank
 
Do you have a fuel pressure gauge? If not, a gauge installed just before the IP would be very important, since knowing what pressure you are dealing with would tell you a lot.

Don
 
Howdy BZ welcome to the forum :welcome2:

Don't give up ship just yet these 6.5s aren't as daunting as they 1st appear just takes some systematic step by step troubleshooting to keep from buying stuff you don't need the TRL has a lot of good info to start you on the learning curve. http://www.thetruckstop.us/forum/forumdisplay.php?218-6-2-and-6-5-Technical-Reference-Library

Bad lift pump unless you have a weak IP will not keep you from starting, but combined with bad glows then it starts getting touch & go This from TRL will help you determine if lift is an issue http://www.thetruckstop.us/forum/sh...t-Pumps-amp-OPS-operation-and-troubleshooting

This will help you sort out gnd issues http://www.thetruckstop.us/forum/showthread.php?17457-Grounds-what-are-they-amp-where-are-they

Copy/paste this into your next reply will help fill in some of the blanks http://www.thetruckstop.us/forum/showthread.php?6300-6-5-Engine-Diagnostic-Troubleshooting-Checklist

Some pics of what you are looking at under the hood http://www.thetruckstop.us/forum/showthread.php?9494-Part-Locations

Sometimes ignition switch is culprit http://www.thetruckstop.us/forum/showthread.php?29858-How-To-Replace-ignition-key-switch

Thought we had this here long ago apparently we forgot to add it http://www.thetruckstop.us/forum/showthread.php?36952-PMD-FSD&p=423853#post423853 PMD/FSD is a a possibility but also more costly to guess at so lets have a look at the "free things we can check 1st,

I went looking for pics for glow plug & relay trouble shooting apparently that never got posted as a TRL thread either it's late here and supposed to rain tomorrow so maybe a good project for a rainy day :) Hey check your PMs I sent you my # we can chat about your hard start one on one
 
Check grounds and they all seem to be good. Also checked LP and it seems ok. GP on drivers side seem ok but have what looks like rust on them. Will change all GPs today. Also going to change fuel filter. I could not find anything on how to change the Fuel Filter on the site. If anyone could help out with this info I would appreciate it.

Thanks to Turbine Doc for all of his help yesterday!
 
Replaced all GP today. Passenger side looked worse than driver side. Tips were greenish. Tried to start and it actually started and ran for about 2 minutes an then shut down again. Have not changed the Fuel Filter. Not exactly sure how. Don't have gauges to check pressure but have a friend I can borrow some from.
 
Hey Dan easy to replace fuel filter I just tried to call no answer your end. Loosen black lock ring turn CCW (Lefty-loosey) you may have to LIGHTLY tap it around to free up once ring is off filter element lifts out, replacement filter is indexed wide slot to wide tab, small black cap on top is vent, after changing filter with test jumper to 12V as in the troubleshooting thread prime the new element with cap open.

Fuel filter OEM Stanadyne style element.jpg
 
Last edited:
Sorry for not posting sooner.

Finally got the fuel filter replaced Sunday evening with help for Turbine Doc. After getting all of the air out of the fuel system the truck is up and running. Has started up right away every time since. Have drivin a couple of times and it cut off on me once and started right back up. Has stumbled two other times but not cut off. Other than those 3 incidents everything else seems fine. Will get another fuel filter and swap out again in about a week. Seems that the fuel filter was the main culprit in all of this. I found out from my son that he had purchased fuel twice at the station that apparently has a reputation for having water in it.:mad2:

Thanks to everyone for their help:thumbsup:. I will chalk this one up to a diesel learning experience.

Now for the next question. What can/should I do to make my truck better? (other than moving PMD)
 
Whenever I have an issue, I usually start by running about 3/4 gallon of fuel out of the T drain and into a gallon pickle jar. Leave it sit about 20 minutes and look for crud and water bubbles on the bottom. Sometimes you can see the crud come out of the drain hose.

That testes the lift pump and checks your fuel all in one shot.

I also try at all times to have a spare fuel filter in every vehicle at all times.

For longevity I would install a bypass filter and switch to 5w30 Amsoil diesel oil - but then that's just me. I do it on every vehicle.

Try to be particular about where you buy diesel. I like to buy from truck stops that are recommended by truckers
 
Call your state department of weights and measures and have them check the station for working water alarms etc. Save someone else the problems.

You should get some biocide for the fuel to make sure any bugs get and stay dead from the water.

Use your water drain on the filter to a glass jar. Jump the lift pump and see how much water you are still getting. You may have to drop the tank to get the water out. I recommend you go to the extreme NOW to get the water out of the system as it does damage to the injection pump and injectors. The factory filter isn't that good at stopping water. Don't "play with it" and see how much water the filter is picking up, get the water out of the tank! The station may be responsible for paying to get the water out of your tank.

The ideal setup is removing the tank sock, walbro lift pump, and use the screen in the walbro or use a Cat water separator prefilter. The Cat water separator will stop water vs. the factory filter - I have seen it work firsthand.
 
Before I changed the fuel filter I drained about 2 gallons in to a quart jar and let it sit each time and had no signs of water. I plan on changing the filter again just to be safe.
 
There is about 1/2" to 1" in the bottom of the tank that the fuel pickup doesn't get. Designed this way to allow some water to be in the tank and not cause issues. You likely still have water in the tank. Slosh it just right and you can pick more of it up while driving. Any water that has fallen off the fuel filter into the bottom will come out in the 1st quart out of the water drain. No need to pump gallons out.
 
Do you have anymore info or links to the Cat water separator prefilter?

WarWagon said:
Call your state department of weights and measures and have them check the station for working water alarms etc. Save someone else the problems.

You should get some biocide for the fuel to make sure any bugs get and stay dead from the water.

Use your water drain on the filter to a glass jar. Jump the lift pump and see how much water you are still getting. You may have to drop the tank to get the water out. I recommend you go to the extreme NOW to get the water out of the system as it does damage to the injection pump and injectors. The factory filter isn't that good at stopping water. Don't "play with it" and see how much water the filter is picking up, get the water out of the tank! The station may be responsible for paying to get the water out of your tank.

The ideal setup is removing the tank sock, walbro lift pump, and use the screen in the walbro or use a Cat water separator prefilter. The Cat water separator will stop water vs. the factory filter - I have seen it work firsthand.
Click to expand...
 
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