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6.5 Engine Diagnostic Troubleshooting Checklist
Copy and paste this checklist into a new post, then answer all the questions by typing in your data into the (red) blanks as indicated - click in the middle of the blank, start typing.
Problem: Explain your problem in concise language (ie: Cranks but won’t fire). Quits whenever it wants to_________________________
Demographics: tell us about your truck and your ambient conditions:
- Year: _1996_Sierra SLT Ex. cab long bed 4X4____
- Truck model and class (ie: c2500) _2500 8600 gvw________
- Automatic or Standard _auto- 4l80e_________
- Mileage: (indicate miles or km) _145,000________
- Replaced parts and mods (IP, PMD, chip/PCM, TM, injectors etc) _IP 3 years ago, injectors 3 yrs ago, LP-PMD- fuel tank and lines May 09' __________
- Model: ‘S’ or ‘F’ engine, NA or Turbo, EGR? _"F" Turbo non egr_____________
- Ambient outside temp: (indicate *C or *F) _80f or 0f, does not matter_________
- What fuel are you using? (#1 Diesel, #2 Diesel, Bio, VO, WVO, etc) _# 2 Diesel________
- What fuel additives are you using? Power Service Cetane Boost year round___________
- Where are you located? _Covington, Ky. just south of Cincinnati, Oh.____________
General maintenance: inspect and evaluate the condition of each. When were they last changed?
- Air filter May 09_________
- Fuel filter _May 09________
- CDR Valve? _3 yrs ago________
- Coolant – last flushed/replaced at Replaced dexcool with regular green 3 yrs ago____________
- Oil – synthetic/regular, changed at _Rotella 15w40 May 09__________
- Batteries – state of charge, (matched set) replaced at _Feb 09, matched set, fully charged____________
- Battery cables and grounds (removed, cleaned and tightened): __Original cables, cleaned yearly____________
- Glow Plugs - how many miles on them? _SS Diesel with new controller, 10,09________ What type? __quick heat___________
- Injectors - last changed at __Rebuilt GM replaced 3 yrs ago_____________
History: (Describe how the problem first appeared.)
- What were you doing when it happened? _Driving_____________
- How was the truck running fine before this problem appeared? _Good____________
- Has this problem ever happened before? _Yes ______________________
- Describe any related factors that might be part of the problem. __none____________
- Have you checked for DTC (Diagnostic Trouble Codes)? (Y.N) no codes____ And? ________
Diagnostics:
1] Starting:
1a] Does the engine start? _Yes, every morning________
1b] Does the engine crank over? __Yes______
1c] Are your batteries fully charged? _Yes________
1d] Have you removed, cleaned, and tightened all battery connections? _Yes_______
1e] Does your Wait to Start light come on for a time? How long? _yes, normal time________
1f] Does your glow plug light come on? _have not noticed________ For how long? ___N/A______
1g] Do you see smoke from the exhaust while cranking? What color? _have not noticed_______
1h] Does the Service Engine Light Glow during Start/bulb check? _have not noticed_______
2] Fuel Issues (if not running):
2a] Can you hear your lift pump working? __Yes__________
2b] Do you get a steady flow of fuel from the water drain (T-handle) ? __Yes_______
2c] Loosen the inlet line from the IP – is fuel coming out (Lift Pump on)? __Yes, gauge before IP, 8 psi with key on_________
2d] Loosen an injector line and crank the engine - does fuel come out? _Yes________
2e] Do you hear a vacuum (hiss) when you remove the fuel cap? __Yes, new locking cap replaced 2, 09_________
3] PMD / IP Issues
3a] Location of PMD (on pump, on intake, remote mounted) remote mounted on SS Diesel heatsink, New Stanadyne "Grey" updated model___________
3b] Condition of Extension harness (if used) Vendor or Homemade? _Yes from PMD Cable with Gold ends________
3c] Condition of grounds / ground wires to IP / PMD. Check Harness. _all clean and tight________
3d] PMD Make: _Stanadyne upgraded "Grey" model_________
3e] PMD Age: _New, 5 09____________
4] Stalling Issues
4a] Do you experience stalling only when hot? no, after truck is running five minutes or five hours___________
4b] Does it stall under particular circumstances? (ie hit bump, or on accel) _under acceleration, idling, hot or cold outside_____
4c] Does pouring cool water over the IP seem to help with restarting? __have not done this_______
4d] Is stalling momentary (engine recovers)? _sometimes it will start right up and other times after sitting for two to three minutes________
4e] Does SES light come on when engine hiccups? __no_______
4f] Does cruise control quit working when engine hiccups? _never use cruise control__________
4g] Does re-starting seem to reset engine, restoring cruise and power? yes_______
4h] Changes to dash lights or instruments during stalling events? __no_________
5] Running Issues
5a] On cold start, does upper rad hose get hard before engine warms up? _have not noticed______
5b] Any bubbles or oil film in coolant overflow tank? _no______
5c] Any white slime on oil surfaces (dipstick, CDR, oil Fill cap)? _no_________
5d] Excessive white smoke from exhaust on cold start? _no________
5e] Excessive black smoke from exhaust under hard acceleration? _no_________
6] Performance Issues
6a] Do you have gauges (boost, EGT) ? yes, fuel pressure under hood before IP, 8 psi with key on__________
6b] Maximum boost under load? ___unknown_________
6c] Have you added a performance PCM (reflash) or Chip? _no_____________
6d] Have you changed exhaust / downpipe / crossover? _crossover with Dealer installed pipe in 05_______________
6e] Wastegate – mechanical or vacuum (OEM)? _vacuum, original wastegate, new vacuum pump 3 yrs ago____________
7] Temperature-related Issues:
7a] Single or dual thermostats? _single 180 f_________
7b] Have you replaced them lately? Manufacturer of replacements? _yes, Delco,replaced 09________
7c] Have you pulled and cleaned Radiator and coolers lately? _no___________
7d] Have you replaced the fan clutch? Manufacturer of replacement? _no_______
7e] (winter) Have you tested your antifreeze? Good to what temp? _yes, - 40_________
7f] (winter) Are you using a winter grille cover? _no __________
List and describe any other factors which are not addressed in this checklist. We can’t see, hear, smell, or touch your truck, so the more descriptive information you can give, the more likely it is that somebody can assist you.
I purchased this truck in 2000 with 59,000 miles on it. I have replaced the IP twice, the last one three yrs. ago when the "service throttle soon" light came on. I tow a 16 ft. trailer all summer long and plow snow in the winter. In may 09 I replace the fuel tank, sending unit, lines and LP and filter. The quitting problem went away but resurfaced in Oct. 09 and then ran fine until Jan. 8th while plowing snow._________________________________
__________________
Please include your vehicle details in your signature. Click here to fill out yours.
If you need assistance with your 6.5TD, please copy our Diagnostic Checklist and start a new thread by pasting it and filling it out in detail.
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=================ΜΟΛΩΝ ΛΑΒΕ==================
Copy and paste this checklist into a new post, then answer all the questions by typing in your data into the (red) blanks as indicated - click in the middle of the blank, start typing.
Problem: Explain your problem in concise language (ie: Cranks but won’t fire). Quits whenever it wants to_________________________
Demographics: tell us about your truck and your ambient conditions:
- Year: _1996_Sierra SLT Ex. cab long bed 4X4____
- Truck model and class (ie: c2500) _2500 8600 gvw________
- Automatic or Standard _auto- 4l80e_________
- Mileage: (indicate miles or km) _145,000________
- Replaced parts and mods (IP, PMD, chip/PCM, TM, injectors etc) _IP 3 years ago, injectors 3 yrs ago, LP-PMD- fuel tank and lines May 09' __________
- Model: ‘S’ or ‘F’ engine, NA or Turbo, EGR? _"F" Turbo non egr_____________
- Ambient outside temp: (indicate *C or *F) _80f or 0f, does not matter_________
- What fuel are you using? (#1 Diesel, #2 Diesel, Bio, VO, WVO, etc) _# 2 Diesel________
- What fuel additives are you using? Power Service Cetane Boost year round___________
- Where are you located? _Covington, Ky. just south of Cincinnati, Oh.____________
General maintenance: inspect and evaluate the condition of each. When were they last changed?
- Air filter May 09_________
- Fuel filter _May 09________
- CDR Valve? _3 yrs ago________
- Coolant – last flushed/replaced at Replaced dexcool with regular green 3 yrs ago____________
- Oil – synthetic/regular, changed at _Rotella 15w40 May 09__________
- Batteries – state of charge, (matched set) replaced at _Feb 09, matched set, fully charged____________
- Battery cables and grounds (removed, cleaned and tightened): __Original cables, cleaned yearly____________
- Glow Plugs - how many miles on them? _SS Diesel with new controller, 10,09________ What type? __quick heat___________
- Injectors - last changed at __Rebuilt GM replaced 3 yrs ago_____________
History: (Describe how the problem first appeared.)
- What were you doing when it happened? _Driving_____________
- How was the truck running fine before this problem appeared? _Good____________
- Has this problem ever happened before? _Yes ______________________
- Describe any related factors that might be part of the problem. __none____________
- Have you checked for DTC (Diagnostic Trouble Codes)? (Y.N) no codes____ And? ________
Diagnostics:
1] Starting:
1a] Does the engine start? _Yes, every morning________
1b] Does the engine crank over? __Yes______
1c] Are your batteries fully charged? _Yes________
1d] Have you removed, cleaned, and tightened all battery connections? _Yes_______
1e] Does your Wait to Start light come on for a time? How long? _yes, normal time________
1f] Does your glow plug light come on? _have not noticed________ For how long? ___N/A______
1g] Do you see smoke from the exhaust while cranking? What color? _have not noticed_______
1h] Does the Service Engine Light Glow during Start/bulb check? _have not noticed_______
2] Fuel Issues (if not running):
2a] Can you hear your lift pump working? __Yes__________
2b] Do you get a steady flow of fuel from the water drain (T-handle) ? __Yes_______
2c] Loosen the inlet line from the IP – is fuel coming out (Lift Pump on)? __Yes, gauge before IP, 8 psi with key on_________
2d] Loosen an injector line and crank the engine - does fuel come out? _Yes________
2e] Do you hear a vacuum (hiss) when you remove the fuel cap? __Yes, new locking cap replaced 2, 09_________
3] PMD / IP Issues
3a] Location of PMD (on pump, on intake, remote mounted) remote mounted on SS Diesel heatsink, New Stanadyne "Grey" updated model___________
3b] Condition of Extension harness (if used) Vendor or Homemade? _Yes from PMD Cable with Gold ends________
3c] Condition of grounds / ground wires to IP / PMD. Check Harness. _all clean and tight________
3d] PMD Make: _Stanadyne upgraded "Grey" model_________
3e] PMD Age: _New, 5 09____________
4] Stalling Issues
4a] Do you experience stalling only when hot? no, after truck is running five minutes or five hours___________
4b] Does it stall under particular circumstances? (ie hit bump, or on accel) _under acceleration, idling, hot or cold outside_____
4c] Does pouring cool water over the IP seem to help with restarting? __have not done this_______
4d] Is stalling momentary (engine recovers)? _sometimes it will start right up and other times after sitting for two to three minutes________
4e] Does SES light come on when engine hiccups? __no_______
4f] Does cruise control quit working when engine hiccups? _never use cruise control__________
4g] Does re-starting seem to reset engine, restoring cruise and power? yes_______
4h] Changes to dash lights or instruments during stalling events? __no_________
5] Running Issues
5a] On cold start, does upper rad hose get hard before engine warms up? _have not noticed______
5b] Any bubbles or oil film in coolant overflow tank? _no______
5c] Any white slime on oil surfaces (dipstick, CDR, oil Fill cap)? _no_________
5d] Excessive white smoke from exhaust on cold start? _no________
5e] Excessive black smoke from exhaust under hard acceleration? _no_________
6] Performance Issues
6a] Do you have gauges (boost, EGT) ? yes, fuel pressure under hood before IP, 8 psi with key on__________
6b] Maximum boost under load? ___unknown_________
6c] Have you added a performance PCM (reflash) or Chip? _no_____________
6d] Have you changed exhaust / downpipe / crossover? _crossover with Dealer installed pipe in 05_______________
6e] Wastegate – mechanical or vacuum (OEM)? _vacuum, original wastegate, new vacuum pump 3 yrs ago____________
7] Temperature-related Issues:
7a] Single or dual thermostats? _single 180 f_________
7b] Have you replaced them lately? Manufacturer of replacements? _yes, Delco,replaced 09________
7c] Have you pulled and cleaned Radiator and coolers lately? _no___________
7d] Have you replaced the fan clutch? Manufacturer of replacement? _no_______
7e] (winter) Have you tested your antifreeze? Good to what temp? _yes, - 40_________
7f] (winter) Are you using a winter grille cover? _no __________
List and describe any other factors which are not addressed in this checklist. We can’t see, hear, smell, or touch your truck, so the more descriptive information you can give, the more likely it is that somebody can assist you.
I purchased this truck in 2000 with 59,000 miles on it. I have replaced the IP twice, the last one three yrs. ago when the "service throttle soon" light came on. I tow a 16 ft. trailer all summer long and plow snow in the winter. In may 09 I replace the fuel tank, sending unit, lines and LP and filter. The quitting problem went away but resurfaced in Oct. 09 and then ran fine until Jan. 8th while plowing snow._________________________________
__________________
Please include your vehicle details in your signature. Click here to fill out yours.
If you need assistance with your 6.5TD, please copy our Diagnostic Checklist and start a new thread by pasting it and filling it out in detail.
Looking for a 'How-to' thread? Check out the
6.5 Technical Reference Library
=================ΜΟΛΩΝ ΛΑΒΕ==================
hmy1