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6.5 Problems

SUX2BU

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Problem: Explain your problem in concise language (ie: Cranks but won’t fire). Starts and runs fine sometimes. Other times it will run for about 1 1/2 min and then surges/misses and stalls. Stalls while running, but only at low speeds. Runs fine with no missing or surging at 60-70mph. I just put a new CPS on the truck because the code came up and still have problems. It ran fine in the winter, but as soon as it started getting hot out is when the problem started.

Demographics: tell us about your truck and your ambient conditions:

- Year: 1995
- Truck model and class (ie: c2500): K2500
- Automatic or Standard: Automatic
- Mileage: (indicate miles or km): 250,000
- Replaced parts and mods (IP, PMD, chip/PCM, TM, injectors etc): IP, PMD/FSD, Starter, Fuel Filter, CPS.
- Model: ‘S’ or ‘F’ engine, NA or Turbo, EGR?: F Turbo
- Ambient outside temp: (indicate *C or *F): 80-100F
- What fuel are you using? (#1 Diesel, #2 Diesel, Bio, VO, WVO, etc): The kind most gas stations have lol?
- What fuel additives are you using?: I have used some, but I didn't keep the bottle and can't remember the name... used it after the problem thinking I might have clogged injectors, but didn't solve the problem.
- Where are you located?: WV

General maintenance: inspect and evaluate the condition of each. When were they last changed?
- Air filter: I bought the truck for months ago and all I have changed is the CPS and Fuel Filter. I did clean the air filter though recently... was pretty clogged up.
- Fuel filter: Within the last 350miles.
- CDR Valve? _________
- Coolant – last flushed/replaced at _____________
- Oil – synthetic/regular, changed at: Rotella - 600 miles ago and filter.
- Batteries – state of charge, (matched set) replaced at _____________
- Battery cables and grounds (removed, cleaned and tightened): ______________
- Glow Plugs - how many miles on them? _________ What type? _____________
- Injectors - last changed at _______________


History: (Describe how the problem first appeared.)
- What were you doing when it happened?: Driving less then half a mile to get a pack of smokes one day and I stopped at a red let and noticed the engine started to miss. Foolishly ignored it and then when the light turned green I accelrated. Missing was still there.. got about half a block and it started missing bad and surging. Stalled and pulled it to the curb. Tried to restart it, but it wouldn't fire. Let it set for about 2 mins and tried again. Started up and a big plume of white/yellowish smoke rolled out of the exhaust. Tried getting it to a parking lot but stalled again... walked to the store and called a tow truck to give me a pull to a parking lot. Was about an hour before I got it pulled. Started it back up and ran great... got me home without any issues!?
- How was the truck running fine before this problem appeared?: Yes... I had just driven it 350 miles on a business trip to Virginia over the WV mountains... not one single problem.
- Has this problem ever happened before?: No
- Describe any related factors that might be part of the problem.: I really can't think of any.
- Have you checked for DTC (Diagnostic Trouble Codes)? (Y.N) Yes And?: Four codes came up. Code 18 (Not sure why since the pump it virtually new), Code 19 (Replaced, but code is still there), Code 29, and a code that has to do with my turbo... one of the senors. Can't remember which one sorry :(


Diagnostics:

1] Starting:
1a] Does the engine start?: Yes
1b] Does the engine crank over?: Yes
1c] Are your batteries fully charged?: Yes
1d] Have you removed, cleaned, and tightened all battery connections?: No
1e] Does your Wait to Start light come on for a time? How long?: No
1f] Does your glow plug light come on?: Yes For how long?: 5-10 Seconds
1g] Do you see smoke from the exhaust while cranking? What color?: Sometimes black and sometimes white.
1h] Does the Service Engine Light Glow during Start/bulb check?: Yes

2] Fuel Issues (if not running):
2a] Can you hear your lift pump working? ____________
2b] Do you get a steady flow of fuel from the water drain (T-handle) ? _________
2c] Loosen the inlet line from the IP – is fuel coming out (Lift Pump on)? ___________
2d] Loosen an injector line and crank the engine - does fuel come out? _________
2e] Do you hear a vacuum (hiss) when you remove the fuel cap? ___________

3] PMD / IP Issues
3a] Location of PMD (on pump, on intake, remote mounted): On Pump I guess. Are we talking about the little black box or the grey one?
3b] Condition of Extension harness (if used) Vendor or Homemade? _________
3c] Condition of grounds / ground wires to IP / PMD. Check Harness. _________
3d] PMD Make: ___________
3e] PMD Age: _____________

4] Stalling Issues
4a] Do you experience stalling only when hot?: Both
4b] Does it stall under particular circumstances? (ie hit bump, or on accel): Accel or Idle (Low Speeds)
4c] Does pouring cool water over the IP seem to help with restarting? _________
4d] Is stalling momentary (engine recovers)? _________
4e] Does SES light come on when engine hiccups? _________
4f] Does cruise control quit working when engine hiccups? ___________
4g] Does re-starting seem to reset engine, restoring cruise and power? _________
4h] Changes to dash lights or instruments during stalling events? ___________

5] Running Issues
5a] On cold start, does upper rad hose get hard before engine warms up? _______
5b] Any bubbles or oil film in coolant overflow tank? _______
5c] Any white slime on oil surfaces (dipstick, CDR, oil Fill cap)? __________
5d] Excessive white smoke from exhaust on cold start?: Just a little usually
5e] Excessive black smoke from exhaust under hard acceleration?: Not really

6] Performance Issues
6a] Do you have gauges (boost, EGT) ?: No
6b] Maximum boost under load? ____________
6c] Have you added a performance PCM (reflash) or Chip? ______________
6d] Have you changed exhaust / downpipe / crossover?: No. Stock Exhaust
6e] Wastegate – mechanical or vacuum (OEM)?: Vacuum

7] Temperature-related Issues:
7a] Single or dual thermostats? ____________
7b] Have you replaced them lately? Manufacturer of replacements? _________
7c] Have you pulled and cleaned Radiator and coolers lately? ____________
7d] Have you replaced the fan clutch? Manufacturer of replacement? ________
7e] (winter) Have you tested your antifreeze? Good to what temp? __________
7f] (winter) Are you using a winter grille cover? ___________

I'm going to be taking some pictures and posting them to help... there are a few things I haven't mentioned here, but I will show with pics. Anything I left blank is because I haven't checked yet. I'm going to check the screen in my fuel filter housing with in the next few days.

Edit: Pics!
I think I did this when I was trying to get my crank sensor out :(. Yes that is one of my glow plug wires. It may have already been like this and I just didn't notice it until I spent a lot of time under the hood.


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I dunno why the previous owner did this. He has what appears to be a ground going into my fuse box and down in-between my fuel solenoid fuse? Any ideas as to why he would do this?


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Okay... I know this is going to sound dumb, but the grey box is the new model PMD right? And the black one on the side of the IP is the old one? Or are they two different things? Cause the black one isn't hooked up.


Uploaded with ImageShack.us

What appears to be one of my sensors to my vacuum pump/turbo.. not sure which one. Again I'm sorry I really don't know much about engines or vehicles in general, but I'm learning :(. The connector to this sensor is bad.. one of the wires is broken. Also, the black vacuum line that runs to this goes to my waste gate correct? I have looked everywhere for a schematic for the vacuum lines for the L65 engine and can't find any :(.


Uploaded with ImageShack.us



Uploaded with ImageShack.us

The original owner had a green vacuum line running from my waste gate to my air box... I'm thinking he did this for some reason... or is it supposed to be like that? The black vacuum line that I have hooked to it now is the one that runs along side the orange line running to earlier said sensor.


Uploaded with ImageShack.us

I'm unsure if any of these said problems are the cause of the surging and missing, but I thought I'd post them anyways just in case.. and yes I'm working on fixing these problems too either way.
 
The vent in the fuel cap is important. Try running with it loose. All the grounds Must be cleaned. It does sound like PMD failure but the other things need to be checked first to eliminate them as possibilities.
 
The vent in the fuel cap is important. Try running with it loose. All the grounds Must be cleaned. It does sound like PMD failure but the other things need to be checked first to eliminate them as possibilities.
I have tried with the cap off/loose and there wasn't a difference. The PMD is the new model grey one mounted up off the engine.. I bought the truck four months ago and the man I bought it off of said he had just changed it along with the IP. Do they normally go bad that quickly? And I will clean the grounds as soon as possible to see if that helps. :)
 
If the grey box wasn't mounted on a heat sink it will fry very quickly. The best place to mount them is behind the license plate inside the front bumper. You will need a extension cable to do that. Check out PMDCABLE.com
 
If the grey box wasn't mounted on a heat sink it will fry very quickly. The best place to mount them is behind the license plate inside the front bumper. You will need a extension cable to do that. Check out PMDCABLE.com
Are there any ways to tell for certain if it is bad before I replace it? I mean I don't want to go and blow $250 on a part if it's not bad... I'm sure you understand this. I have the one that's still mounted to the IP, but I'm guessing that one was the one that went bad before and I found one in my cab in one of the pockets... it might be a spare that the guy had.. so I might try it to see if it works. I know it will eventually need to be remounted though. I just don't have much money at the moment :(
 
There is a way but it's not free either, go to stanadyn web site & search for local dealer, my local dealer sells used PMD's for $50 bucs with a 4 week no questions asked replacement, perfect for a backup & ya should have a spare with ya anyhow. I need to go get another one to have in my Tahoe...I hook em up & test em pronto before I deem them as a reliable backup.

The spare that I carry in my trucks I have mounted on a small computer heat sink that I keep in my glovebox with some zip ties...
 
There is a way but it's not free either, go to stanadyn web site & search for local dealer, my local dealer sells used PMD's for $50 bucs with a 4 week no questions asked replacement, perfect for a backup & ya should have a spare with ya anyhow. I need to go get another one to have in my Tahoe...I hook em up & test em pronto before I deem them as a reliable backup.

The spare that I carry in my trucks I have mounted on a small computer heat sink that I keep in my glovebox with some zip ties...
Hmm.. I'm thinking I might already have one. It's the black one though. It wouldn't hurt to try it I guess :)
 
Well I cleaned my grounds and the screen inside the filter canister. I put everything back together and cranked the truck, but it wouldn't start... it acted like it wanted to the first few cranks, but now it doesn't at all. I'm thinking whatever was going bad has officially bit the dust... it had been getting increasingly harder to get the truck started as of late.
 
You may have gotten air into the fuel system while you were cleaning the screen in the FFM.

Your black PMD won't work in place of the gray one. The connector is different from a black PMD to a gray one. If you want to swap a different PMD to see if that's the problem, you will have to get another gray one.
 
You may have gotten air into the fuel system while you were cleaning the screen in the FFM.

Your black PMD won't work in place of the gray one. The connector is different from a black PMD to a gray one. If you want to swap a different PMD to see if that's the problem, you will have to get another gray one.
That's odd? I just hooked up the black one with the same connector that was on my gray one...? And I opened the air bleed valve for the recommended time with the ignition on, and cranked the truck for 30 seconds. It wouldn't start early this morning either... that's before I had done anything to the truck.
 
They are different connectors.... Is the connector on your truck that plugs into the PMD black or gray?
 

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They are different connectors.... Is the connector on your truck that plugs into the PMD black or gray?
It's black. I found the connector with the gray end on it... apparently new and unused in the back of my truck the other day, but the one the previous owner had it connected to was the black one. I wish I still had his number... I have plenty I would like to ask him.
 
From your explanation of the missing, stalling and the hard starts......Sounds like "Classic" PMD/FSD failure.

Also, as stated above if you ran the other/spare PMD without a heatsink......It's most likely garbage/junk now.

JMO
 
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