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Newbie's first trek into Death Valley

C

coachjpg

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I've seen references to the mess people sometimes find when they remove the intake manifold on a 6.5 TD. They mention decayed vacuum lines, and other items damaged by long-term heat exposure.

I have to replace my corroded fuel lines and failed LP. While I was at it, I figured I should also do FTB. That entails pulling the intake manifold. Once I have the intake manifold off, what should I look for? What should I replace while I have access?

I'm assembling the parts I need for this project, in hopes of minimizing shopping trips while the truck is in pieces. I have the intake manifold gaskets. The fuel line, Walbro, fuel fittings, plenum gasket, vacuum/pressure gauge, needle valve, and fuel fittings are all on order. It sounds like I should also have some vacuum line handy. I'm about to order the FTB kit and NPT tap. What else should I have on hand? What surprises typically lurk in what I've heard people call "Death Valley"?

I did look for threads on this, but came up dry. Perhaps I just don't have the right vocabulary yet. I'd appreciate any pointers.

I have a '99 C3500 6.5TD with manual transmission. Lift pump has power but doesn't move fuel. Fuel line fittings are too corroded to use. I'm planning to put in fuel hose instead. (I hate corrosion.) PO replaced cluch and tranny, and had engine serviced & filters replaced 6 months ago. Truck has frame rust, but drive train is great. (As long as I don't try to bleed water from the filter with a dead LP.)

Thanks,
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Wow - sounds like you've been doing your research! I assume you've been on the WalkingJ website right here on TTS to see what FTB parts they recommend, and on PMDcable's site for things like the Oil Pressure Switch extension... our vendors are very helpful guys with projects like this, even if they aren't selling you parts!

I'd suggest having wire and tools for working with it - the valley of death is hard on wiring harnesses, and you'll never get a better chance to examine your wiring and make repairs than this!

And a camera... take pictures, make a thread of your work, and we'll get your adventures into the 6.5 Technical Library so others may learn!

And Hey-hey-hey ... Be careful out there!
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Dont forget the intake gaskets, upper and lower. Be careful with the injection lines when removing clips and such. You might find long lost nuts and bolts in there, maybe a wrench. Main thing in there is the fuel lines. You can try to inspect wires in the looms and what not.
 
Might want to think about re-locating the fuel filter housing as well. If you are adding new lines this would be the time. Makes filter changes and finding leaks much easier.

There are a few threads around here with pictures.

I ended up running the fuel line outside of the valley as it is much easier to repair and i see no reason to place it back in the factory location.

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If you are replacing the fuel lines all the way to the tank and the truck has seen any road salt ,replace the rear steel brake line that runs in the frame next to the fuel tank. They and the steel fuel lines rust out where the frame starts to bend up to go over the rear axle. I've had 3 trucks rot the lines in the same place.
 
NAPA has "Plenum" and "Intake" gaskets. Are they the same as "upper" and "lower"?

Can anyone point me to a reliable source for the torques I should use in reassembly? I have a sad history of shearing off bolts...

Thanks,
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I recommend replacing both the drain hose and the FTB kit from my site. Also, replace that little hose behind the fuel manager, you'll thank yourself.

Thanks.
 
coachjpg said:
NAPA has "Plenum" and "Intake" gaskets. Are they the same as "upper" and "lower"?

Can anyone point me to a reliable source for the torques I should use in reassembly? I have a sad history of shearing off bolts...

Thanks,
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Click to expand...

That 6.5 Technical Reference Library is a fascinating, oh-so-handy place...

THIS POST is from Matt in Alberta (Alberta Redneck) and should have the info you need.

Jim
 
JiFaire said:
That 6.5 Technical Reference Library is a fascinating, oh-so-handy place...

Agreed, but the intake manifold specs there go through '98. They don't cover my '99.

I do try to exhaust available sources before asking questions.
Click to expand...
 
Ah ... sorry. Your signature still doesn't list your truck and I didn't go back to the first post to check.

My bad.

PS - Bet they're the same specs for 99.
 
Sorry about that. I'd filled out my profile, but overlooked my sig. Fixed.

I agree that the '99 torque specs probably match the '98. If I'm going to be working on this engine, I need to get the right documentation. What do folks here use/recommend, and where's a good source? Do I need the GM service manuals? The books NAPA stocks never cover diesels...

Thanks,
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buddy said:
Dont forget the intake gaskets, upper and lower. Be careful with the injection lines when removing clips and such. You might find long lost nuts and bolts in there, maybe a wrench. Main thing in there is the fuel lines. You can try to inspect wires in the looms and what not.
Click to expand...

Were you watching me? ):h You hit 'em all, left out a missing socket that magically reappeared.:eek:
 
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