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Flakey 6.5

legendman

New Member
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Location
Oakdale,CT
Hi all need some help with my 6.5 dooley

Here is the filled out checklist

Problem: Explain your problem in concise language (ie: Cranks but won’t fire). _Stalls and hesitation when pushing on accel pedal____________________

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

- Year: __1996____
- Truck model and class (ie: c2500) _K3500________
- Automatic or Standard ___Auto_______
- Mileage: (indicate miles or km) __244k_______
- Replaced parts and mods (IP, PMD, chip/PCM, TM, injectors etc) ___PMD________
- Model: ‘S’ or ‘F’ engine, NA or Turbo, EGR? ___Turbo___________
- Ambient outside temp: (indicate *C or *F) __40-50 degress________
- What fuel are you using? (#1 Diesel, #2 Diesel, Bio, VO, WVO, etc) ___# Diesel______
- What fuel additives are you using? _Diesel Kleen__________
- Where are you located? __Connecticut___________

General maintenance: inspect and evaluate the condition of each. When were they last changed?
- Air filter __Replaced_______
- Fuel filter _No idea on last replacement date________
- CDR Valve? __No idea on last replacement date_______
- Coolant – last flushed/replaced at __Never done since I owned it___________
- Oil – synthetic/regular, changed at __10k ago_________
- Batteries – state of charge, (matched set) replaced at ___Good__________
- Battery cables and grounds (removed, cleaned and tightened): ____Couple days ago__________
- Glow Plugs - how many miles on them? __No idea_______ What type? _____________
- Injectors - last changed at ___No idea____________


History: (Describe how the problem first appeared.)
- What were you doing when it happened? ___60 mph on the highway it just stalled out coasted off exit ramp waited a couple minutes and it drove home fine___________
- How was the truck running fine before this problem appeared? ___Fine__________
- Has this problem ever happened before? ___Yes____________________
- Describe any related factors that might be part of the problem. ____Accelerator pedal seems to not work, if I am driving down the road and let off the pedal then get back on the pedal I have to push a lot further on the pedal to get any acceleration or I have to completely let of the pedal and hit it again, sometime I have to push on it a couple times to get it to react__________
- Have you checked for DTC (Diagnostic Trouble Codes)? (Y.N) __N__ And? __No check engine showing______


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? ___Yes_____
1e] Does your Wait to Start light come on for a time? How long? __Yes Normal time 30 seconds I guess_______
1f] Does your glow plug light come on? _________ For how long? _________
1g] Do you see smoke from the exhaust while cranking? What color? __No______

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

3] PMD / IP Issues
3a] Location of PMD (on pump, on intake, remote mounted) __On intake (FSD heatsink)_________
3b] Condition of Extension harness (if used) Vendor or Homemade? ___Looks ok I greased the connections______
3c] Condition of grounds / ground wires to IP / PMD. Check Harness. __Haven't checked these_______
3d] PMD Make: __FSD_________
3e] PMD Age: ____No Idea_________

4] Stalling Issues
4a] Do you experience stalling only when hot? _Yes___________
4b] Does it stall under particular circumstances? (ie hit bump, or on accel) __No____
4c] Does pouring cool water over the IP seem to help with restarting? ___Haven't tried this maybe after a half minute of it sitting it starts back up______
4d] Is stalling momentary (engine recovers)? __No_______
4e] Does SES light come on when engine hiccups? __No_______
4f] Does cruise control quit working when engine hiccups? __Haven't tried the cruise_________
4g] Does re-starting seem to reset engine, restoring cruise and power? ___Yes______
4h] Changes to dash lights or instruments during stalling events? __Yes_________

5] Running Issues
5a] On cold start, does upper rad hose get hard before engine warms up? __Haven't checked this_____
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 gauge________
6b] Maximum boost under load? __7lbs__________
6c] Have you added a performance PCM (reflash) or Chip? __No____________
6d] Have you changed exhaust / downpipe / crossover? __Yes______________
6e] Wastegate – mechanical or vacuum? ___Mechanical___________

7] Temperature-related Issues:
7a] Single or dual thermostats? Not sure___________
7b] Have you replaced them lately? Manufacturer of replacements? ___No______
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? __No________
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.


Trying to figure out if maybe my PMD or Accelerator pedal is bad or possibly both given the mileage that is on the truck.

Thanks all for your help.:thumbsup:
 
In my opinion it sounds a lot like PMD but lets try the cheap stuff first.

Clean your grounds.

If you think the fuel filter has over 20,000 it's time for a change.

Perform the 2a-d tests. You should be able to hear the lift pump rattle away as soon as you turn the key while the glow plugs are cycling.

Plumb a cheap diagnostic fuel pressure gauge into the fuel drain line. Use a long enough piece of line to bring the gauge through the drivers window. You could tape it to the windshield wiper but this can lead to you leaning out the window at 60 trying to grab the gauge when it comes loose (haven't experienced this personally but someone on the forum has) Take it for a drive and observe pressure.

You really need to get the PMD/FSD out of the engine bay. http://www.pmdcable.com/ is a forum vendor that has a good extension at a good price.
 
Thanks for the help, is it bad practice to make my own pmd harness that is longer and I can relocate it out on the front bumper?
 
Packratt gave great advice on all counts. As far as making your own PMD harness, lots of us have done it. There is a post in the 6.5 Technical Library that talks about PMD Extensions (to solder or crimp) which may be of interest. Personally, I would just buy one - saves a lot of playing around and Leroy has a good product there, as was mentioned.
 
LM, when that PMD comes in, I assume you're planning on mounting it on your FSD Cooler and then remoting THAT out behind the bumper?

Hint - make sure you (first) make sure you clean the surface of the PMD cooler thoroughly where it will mate with the PMD, (second) go to a computer shop and buy some heat-sink paste to put between the PMD and the heatsink - I like 'Arctic Silver' compound, (third) fasten the PMD to the heatsink tightly with GOOD fasteners (it needs to clamp tightly, and crappy little screws just can't be tightened enough), and (fourth) seal the PMD to the heatsink with a nice little bead of RTV to keep moisture from wicking into the mated surface.

You probably already knew all that, but it never hurts to re-state stuff that somebody might need to know.
 
JiFaire Thanks for tips on mounting, have a question though, does the pmd need ground?
Should I run a wire back to the battery as a ground wire?
 
The PMD harness is currently grounded to a screw on top of the IP. LEAVE IT THERE. Moving the harness ground to the heatsink causes timing issues.

The heatsink itself will pick up a body ground when you mount it, just don't play with the stock hatness. Make sure the black ground wire goes to the top of the IP and not the Heat sink..
 
The main thing that packrat said that you should do today is replace the fuel filter and clean the canister. Even if the current problem is the PMD you don't know how long that filter has been in there. A clogged fuel filter can cause the same problems as a flakey PMD. Since according to your checklist you don't know how long it has been in there you can follow these steps.

(If you don't know it is located behind the upper intake manifold near the firewall. It has a black plastic grooved ring holding it on the canister.)

1. Remove black ring using a large pair of channel locks or a hammer and flat head screw driver.

2. pull out the filter. Since it has been in for a while it maybe tight.

3. There is a little spring in the bottom of the filter housing that may come out w/ the filter. Check the old filter and make sure it isn't in the bottom of it.

4. Use an old rag to soak up all the fuel remaining in the filter.

5. Look at the bottom of the filter. You will probably see a lot of crap in the bottom. Use a screw driver and a rag to clean it out. I always find it easier to disconnect the hose coming up the back of the engine to the canister as well and the 2 hoses on the front. before you can disconnect them you need to disconnect the 2 bolt holding the canister to the upper intake. I believe they are 15 mm. You will also need to disconnect the plug for the fuel heater.

6. If you tak the canister out clean it w/ brake cleaner to make sure it is nice and clean inside.

7. Put it back together if you took it out.

8. Fill the canister 1/2 way w/ any type of diesel fuel injector cleaner like standyne, power service, etc.

9. Put the flter in and screw the black ring back on. Prime the pump (turning the key to the on position you should hear the lift pump clicking if it doesn't you probably need a new one of those as well) a few times to make sure you get diesel up to the filter.

10. turn the truck over. Let it idle for 5 minutes and let the fuel inj cleaner clean your system.
 
Great point, Rodd... hey, next time you do this, you wanna take pictures? We could use a pictorial How-To-Change-Your-Fuel-Filter thread in the Tech Library!
 
Legendman, are you from WELLINGTON, KS I had someone order a PMD and cable recently. Just wondering if it was you?

Thanks packratt and Jifaire for the referal, very much appreciated. :thumbsup:
 
Great point, Rodd... hey, next time you do this, you wanna take pictures? We could use a pictorial How-To-Change-Your-Fuel-Filter thread in the Tech Library!

The funny thing is I am due for a new fuel filter change. I have been putting it off because the baffle in my tank came loose again and I was going to do them at the same time. I will get some pic's when I do it. My business has been booming for the last 9 months and haven't had time to do anything to my truck or post much here. Hopefully I will find some time in the next few weeks to get it done and documented.
 
Waiting for the new parts to come in, I was looking under the and what do ya know. There is a pmd still on the injection pump, guess previous owner didn't want to deal with the hassle off taken it off.

It also picked up a filter and some power service as Rod requested, I good do a write up when I change it out.
 
Legendman, are you from WELLINGTON, KS I had someone order a PMD and cable recently. Just wondering if it was you?

Thanks packratt and Jifaire for the referal, very much appreciated. :thumbsup:

I only ordered a cable which I got today, Thanks for the quick shipping.

I relocated the PMD front to the front bumper, already had a FSD heatsink so I got some silver thermal compound at Radio Shack to help with the heat transfer.
Took it for about the 40 mile ride tonight and no issues.
Going to get it up on the highway in the next couple days to see how it is.

Not enough time to do the fuel filter yet, maybe this weekend.

Thanks all for the help.
 
I only ordered a cable which I got today, Thanks for the quick shipping.

I relocated the PMD front to the front bumper, already had a FSD heatsink so I got some silver thermal compound at Radio Shack to help with the heat transfer.
Took it for about the 40 mile ride tonight and no issues.
Going to get it up on the highway in the next couple days to see how it is.

Not enough time to do the fuel filter yet, maybe this weekend.

Thanks all for the help.

OK great to hear. I see you added your location under your avatar too. Looks like a nice truck.
 
Update.... Still have an issue, I think the accelerator pedal is acting up.
I give it throttle and it goes. I come to a light and go to give it pedal and nothing or sometimes I have to push way down on the pedal. If I let a couple times it returns to normal. I am going to rip the APP apart, I looked around here for a post on cleaning the contacts in it but couldn't find it. Anybody have any suggestions?

Thanks
 
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