New! Need some 6.5 help

[Larry]

- Truck model and class (ie: c2500) _3500 dually________
- Automatic or Standard _auto_________
- Mileage: (indicate miles or km) _252567_miles_______
- Replaced parts and mods (IP, PMD, chip/PCM, TM, injectors etc) _ip,pmd,ij,turbo,4" exhaust,rebuilt tranny,air breather__________
- Model: ‘S’ or ‘F’ engine, NA or Turbo, EGR? _____F_________
- Ambient outside temp: (indicate *C or *F) __________
- What fuel are you using? (#1 Diesel, #2 Diesel, Bio, VO, WVO, etc) ___#2______
- What fuel additives are you using? _power service__________
- Where are you located? __St.Joe,mo___________

General maintenance: inspect and evaluate the condition of each. When were they last changed?
- Air filter _252500________
- Fuel filter _252500________
- CDR Valve? _250000________
- Coolant – last flushed/replaced at _248000____________
- Oil – synthetic/regular, changed at _252000__rotella 15/40________
- Batteries – state of charge, (matched set) replaced at _248000____________
- Battery cables and grounds (removed, cleaned and tightened): __248000____________
- Glow Plugs - how many miles on them? _15000________ What type? _____?________
- Injectors - last changed at __245000_____________


History: (Describe how the problem first appeared.)
- What were you doing when it happened? _passing another vehicle_____________
- How was the truck running fine before this problem appeared? __perfect___________
- Has this problem ever happened before? ___yes____________________
- Describe any related factors that might be part of the problem. engine hiccups when passing or getting on hard______________
- Have you checked for DTC (Diagnostic Trouble Codes)? (Y.N) __y__ And? __only codes that apear now are turbo boost codes______

[FONT=&quot]
[/FONT] 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? _10 to 15 seconds________
1f] Does your glow plug light come on? _________ For how long? _________
1g] Do you see smoke from the exhaust while cranking? What color? ________
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) __remote mounted_________
3b] Condition of Extension harness (if used) Vendor or Homemade? _vendor/perfect condition________
3c] Condition of grounds / ground wires to IP / PMD. Check Harness. _all perfect condition________
3d] PMD Make: _?__________
3e] PMD Age: __8/09___________

4] Stalling Issues
4a] Do you experience stalling only when hot? __once__about a hundred miles ago________
4b] Does it stall under particular circumstances? (ie hit bump, or on accel) _cruising at 25 miles per hour_____
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? __no_______
4f] Does cruise control quit working when engine hiccups? _dont know__________
4g] Does re-starting seem to reset engine, restoring cruise and power? _no change ________
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? _no______
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? __have some black smoke not excessive________

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? __no____________
6d] Have you changed exhaust / downpipe / crossover? ___yes_____________
6e] Wastegate – mechanical or vacuum (OEM)? __mechanical____________

7] Temperature-related Issues:
7a] Single or dual thermostats? __dual__________
7b] Have you replaced them lately? Manufacturer of replacements? __yes_______
7c] Have you pulled and cleaned Radiator and coolers lately? _yes___________
7d] Have you replaced the fan clutch? Manufacturer of replacement? __yes______
7e] (winter) Have you tested your antifreeze? Good to what temp? __-30________
7f] (winter) Are you using a winter grille cover? __no_________

 

[nvmtnlion]

It appears as if this is a fuel supply issue. I would guess dirty fuel filter, snotty tank sock, or lift pump. Can you post the results of section 2 of the check list please?

 

[Larry]

2] Fuel Issues (if not running):
2a] Can you hear your lift pump working? _yes just replaced it from heath___________
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_________
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? _use to vacuum so bad it sucked the tank in,replaced tank,cap,float ass. and fuel filter about 500 miles ago was running perfect up to a week ago__________

 

[chickenhunterbob]

What year truck?

Do you still have the original electronic filter harness on the IP?

 

[JiFaire]

Sounds like fuel... do you have a fuel pressure gauge adn about 6' of tubing? You can put the gauge on the outlet at the T-handle, run the hose up to your windshield wiper and tape the gauge down so you can see it while driving. Sock, fuel filter, or other blockage will show up when you stomp on it; pressure will drop to zero or even negative if you have enough blockage.

Rig costs ~$10 at Harbour freight, iirc... best little diagnostic tool you can have.

on edit - CHBob has a good question, too... although not common in OBD-II trucks, some do have an IP Electronic filter harness... that needs to be removed.

 

[ak diesel driver]

my 96 had one

 

[iamdave0887]

my 96 had one

x2. my 96 had the OS filter harness too.

 

[Larry]

I thank you all for the advice,but now i have bigger problems,i blew a head gasket on the way home from work,oh well such as life.

 

[Larry]

my truck is a 96 and is the filter in the wiring harness that plugs in to the pmd.Thank you for your help

 

[ak diesel driver]

no it goes to the optical sensor on top of the ip

 

[Larry]

I have my intake manifold off,getting ready to pull the heads.I will look for this filter.I hope I don't find any thing bad when I pull the heads off

 

[Larry]

can the filter be removed permanently

 

[ak diesel driver]

yes

 

[buddy]

Your stumbling could be fuel supply issues, or an air leak that becomes apparent when under load (because pressure drops), or just defueling from turbo codes. Need a boost fooler, or aftermarket PCM to fix the defueling.

The stalling is likely as stated, some type of fuel issue. Please post the exact codes that you get.

Having that huge vacuum might suggest you had an air leak, maybe fixed from replacing stuff, or maybe just less apparant. Check the fuel supply line from the tank, and the return line.

Also, you should add a lubricant better than PS to your ULSD, like some TCW3 2-stroke oil, or SAE30 non detergent oil.