maximsafety
Big red
Greetings all,
Back from working night shifts and thanks to all of you I solved the problem with the short glow plug run time. It is amazing what a loose connection will or won't do!):h Now I have a much bigger problem:mad2: About two weeks ago I was just cruising down the road at around 35 MPH when the truck suddenly surged and the SES came on and stayed on. Got home, shut it down, restarted, and no SES light (checked with my GM tech 1 scanner and no history of codes
) and it ran fine for a moment then started surging like crazy, then stopped. Over the next two weeks the problem has gotten worse and now the truck won't start at all!!! Have checked/troubleshoot everything I can think of (see sheet below). I have filled out the diagnostics sheet with everything that has been done to the truck as well as what has been checked. I'm stumped guys, I think my rebuilt IP is toast with around 1500 miles, but before I remove and send back I would like to get the panel of experts involved:thumbsup:
1995 Silverado 4X4 one ton dually, Marine injectors, turbo boost controller, 4" exhaust, cold air intake, #9 resistor, Heath HPT chip, Duramax fan w/HD fan clutch, 130 gpm water pump w/180 thermostat, Mag-Hytec trans & diff pans, pyrometer, trans temp & boost gauge (running 14 psi max boost). Pullin a 98 Alfa Ideal w/two slides (10,000 +lbs.) and the beast does'nt complain!
Problem: Explain your problem in concise language (ie: Cranks but won’t fire). __Cruising @ 35mph truck surged, check engine light came on. Stopped the truck, shut it down and restarted and it was fine. Got home,shut it down, then started truck again and started surging worse and worse (over a period of two weeks), now won’t start at all (cranks but won’t fire)__________________________
Demographics: tell us about your truck and your ambient conditions:
- Year: ___1995___
- Truck model and class (ie: c2500) 3500 one ton dually_________
- Automatic or Standard ___Auto_______
- Mileage: (indicate miles or km) __154000_______
- Replaced parts and mods (IP, PMD, chip/PCM, TM, injectors etc) 1,500 miles on Rebuilt IP from Pensecola Diesel, Relocated new PMD behind bumper, Heath Diesel chip W/fresh PCM TM?_Heath Mechanical turbo boost controller, marine injectors, Health crossover & 4” exhaust, HO water pump, Duramax fan & HD fan clutch, 180 degree thermostat. All work and parts done within the last 2,000 miles_________
- Model: ‘S’ or ‘F’ engine, NA or Turbo, EGR? ___F Engine, turbo, no EGR___________
- Ambient outside temp: (indicate *C or *F) ____Average this time of year 70’s to 80 plus______
- What fuel are you using? (#1 Diesel, #2 Diesel, Bio, VO, WVO, etc) _____#2 Diesel____
- What fuel additives are you using? ___Diesel Power Service________
- Where are you located? _____Northern California (San Francisco Bay Area)________
General maintenance: inspect and evaluate the condition of each. When were they last changed?
- Air filter ___Less than 2000 miles K&N______
- Fuel filter ___Brand New______
- CDR Valve? __Less Than 2000 miles_______
- Coolant – last flushed/replaced at ______Less than 100_______
- Oil – synthetic/regular, changed at ____Royal Purple 15/40 less than 1500 miles_______
- Batteries – state of charge, (matched set) replaced at _____Unknown when replaced, but load tested, fully charged and in good condition matched set________
- Battery cables and grounds (removed, cleaned and tightened): ____Yes to all__________
- Glow Plugs - how many miles on them? ___less than 2000______ What type? _____duraterm________
- Injectors - last changed at ______Marine injectors less than 2000 mile_________
History: (Describe how the problem first appeared.)
- What were you doing when it happened? _____Cruising at 35 MPH_________
- How was the truck running fine before this problem appeared? ____Perfect_________
- Has this problem ever happened before? ________Never_______________
- Describe any related factors that might be part of the problem. _____Did injection pump test per Bill Heath @ Health Diesel, results less than perfect_________
- Have you checked for DTC (Diagnostic Trouble Codes)? (Y.N) _Y with GM Tech scan___ And? ____No history of codes per scanner____
Diagnostics:
1] Starting:
1a] Does the engine start? _Not anymore________
1b] Does the engine crank over? _Yes_______
1c] Are your batteries fully charged? ___Yes______
1d] Have you removed, cleaned, and tightened all battery connections? __Completely______
1e] Does your Wait to Start light come on for a time? How long? __Yes, around ten sec_______
1f] Does your glow plug light come on? ____N/A_____ 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? _____Yes, brand new carter installed less than 100 miles ago_______
2b] Do you get a steady flow of fuel from the water drain (T-handle) ? ___Perfect before the running problem______
2c] Loosen the inlet line from the IP – is fuel coming out (Lift Pump on)? ____How do I do that with a 95 when I have to get the oil pressure up for the pump to work?_______
2d] Loosen an injector line and crank the engine - does fuel come out? ___Have not done yet______
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) __Remote mounted behind bumper_________
3b] Condition of Extension harness (if used) Vendor or Homemade? ____Vendor EDAM, checked by removing and pluging PMD in directly, same problem no change_____
3c] Condition of grounds / ground wires to IP / PMD. Check Harness. __Very good condition, just to make sure replaced PMD with new PMD and no change_______
3d] PMD Make: ___Standyne________
3e] PMD Age: ___Brand new__________
4] Stalling Issues
4a] Do you experience stalling only when hot? _____N/A__Truck never stalled_____
4b] Does it stall under particular circumstances? (ie hit bump, or on accel) __N/A____
4c] Does pouring cool water over the IP seem to help with restarting? ____N/A_____
4d] Is stalling momentary (engine recovers)? ____N/A_____
4e] Does SES light come on when engine hiccups? ___Yes______
4f] Does cruise control quit working when engine hiccups? ___Unknown________
4g] Does re-starting seem to reset engine, restoring cruise and power? ____Yes_____
4h] Changes to dash lights or instruments during stalling events? ____Just the check light when surging occurs_______
5] Running Issues
5a] On cold start, does upper rad hose get hard before engine warms up? ___N/A____
5b] Any bubbles or oil film in coolant overflow tank? ___N/A____
5c] Any white slime on oil surfaces (dipstick, CDR, oil Fill cap)? ____N/A______
5d] Excessive white smoke from exhaust on cold start? __N/A_______
5e] Excessive black smoke from exhaust under hard acceleration? ____N/A______
6] Performance Issues
6a] Do you have gauges? ___Yes________
6b] Maximum boost under load? ___Just under_14 psi________
6c] Have you added a performance PCM (reflash) or Chip? _____Yes_________
6d] Have you changed exhaust / downpipe / crossover? _______Yes_________
6e] Wastegate – mechanical or vacuum? ___Mechanical___________
7] Temperature-related Issues:
7a] Single or dual thermostats? ______Single______
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? ___Yes,Don’t remember what temp, but truck (when it was running)was solid @ 180 even under load, has never overheated _______
7f] (winter) Are you using a winter grille cover? ___N/A________
Back from working night shifts and thanks to all of you I solved the problem with the short glow plug run time. It is amazing what a loose connection will or won't do!):h Now I have a much bigger problem:mad2: About two weeks ago I was just cruising down the road at around 35 MPH when the truck suddenly surged and the SES came on and stayed on. Got home, shut it down, restarted, and no SES light (checked with my GM tech 1 scanner and no history of codes
) and it ran fine for a moment then started surging like crazy, then stopped. Over the next two weeks the problem has gotten worse and now the truck won't start at all!!! Have checked/troubleshoot everything I can think of (see sheet below). I have filled out the diagnostics sheet with everything that has been done to the truck as well as what has been checked. I'm stumped guys, I think my rebuilt IP is toast with around 1500 miles, but before I remove and send back I would like to get the panel of experts involved:thumbsup:1995 Silverado 4X4 one ton dually, Marine injectors, turbo boost controller, 4" exhaust, cold air intake, #9 resistor, Heath HPT chip, Duramax fan w/HD fan clutch, 130 gpm water pump w/180 thermostat, Mag-Hytec trans & diff pans, pyrometer, trans temp & boost gauge (running 14 psi max boost). Pullin a 98 Alfa Ideal w/two slides (10,000 +lbs.) and the beast does'nt complain!
Problem: Explain your problem in concise language (ie: Cranks but won’t fire). __Cruising @ 35mph truck surged, check engine light came on. Stopped the truck, shut it down and restarted and it was fine. Got home,shut it down, then started truck again and started surging worse and worse (over a period of two weeks), now won’t start at all (cranks but won’t fire)__________________________
Demographics: tell us about your truck and your ambient conditions:
- Year: ___1995___
- Truck model and class (ie: c2500) 3500 one ton dually_________
- Automatic or Standard ___Auto_______
- Mileage: (indicate miles or km) __154000_______
- Replaced parts and mods (IP, PMD, chip/PCM, TM, injectors etc) 1,500 miles on Rebuilt IP from Pensecola Diesel, Relocated new PMD behind bumper, Heath Diesel chip W/fresh PCM TM?_Heath Mechanical turbo boost controller, marine injectors, Health crossover & 4” exhaust, HO water pump, Duramax fan & HD fan clutch, 180 degree thermostat. All work and parts done within the last 2,000 miles_________
- Model: ‘S’ or ‘F’ engine, NA or Turbo, EGR? ___F Engine, turbo, no EGR___________
- Ambient outside temp: (indicate *C or *F) ____Average this time of year 70’s to 80 plus______
- What fuel are you using? (#1 Diesel, #2 Diesel, Bio, VO, WVO, etc) _____#2 Diesel____
- What fuel additives are you using? ___Diesel Power Service________
- Where are you located? _____Northern California (San Francisco Bay Area)________
General maintenance: inspect and evaluate the condition of each. When were they last changed?
- Air filter ___Less than 2000 miles K&N______
- Fuel filter ___Brand New______
- CDR Valve? __Less Than 2000 miles_______
- Coolant – last flushed/replaced at ______Less than 100_______
- Oil – synthetic/regular, changed at ____Royal Purple 15/40 less than 1500 miles_______
- Batteries – state of charge, (matched set) replaced at _____Unknown when replaced, but load tested, fully charged and in good condition matched set________
- Battery cables and grounds (removed, cleaned and tightened): ____Yes to all__________
- Glow Plugs - how many miles on them? ___less than 2000______ What type? _____duraterm________
- Injectors - last changed at ______Marine injectors less than 2000 mile_________
History: (Describe how the problem first appeared.)
- What were you doing when it happened? _____Cruising at 35 MPH_________
- How was the truck running fine before this problem appeared? ____Perfect_________
- Has this problem ever happened before? ________Never_______________
- Describe any related factors that might be part of the problem. _____Did injection pump test per Bill Heath @ Health Diesel, results less than perfect_________
- Have you checked for DTC (Diagnostic Trouble Codes)? (Y.N) _Y with GM Tech scan___ And? ____No history of codes per scanner____
Diagnostics:
1] Starting:
1a] Does the engine start? _Not anymore________
1b] Does the engine crank over? _Yes_______
1c] Are your batteries fully charged? ___Yes______
1d] Have you removed, cleaned, and tightened all battery connections? __Completely______
1e] Does your Wait to Start light come on for a time? How long? __Yes, around ten sec_______
1f] Does your glow plug light come on? ____N/A_____ 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? _____Yes, brand new carter installed less than 100 miles ago_______
2b] Do you get a steady flow of fuel from the water drain (T-handle) ? ___Perfect before the running problem______
2c] Loosen the inlet line from the IP – is fuel coming out (Lift Pump on)? ____How do I do that with a 95 when I have to get the oil pressure up for the pump to work?_______
2d] Loosen an injector line and crank the engine - does fuel come out? ___Have not done yet______
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) __Remote mounted behind bumper_________
3b] Condition of Extension harness (if used) Vendor or Homemade? ____Vendor EDAM, checked by removing and pluging PMD in directly, same problem no change_____
3c] Condition of grounds / ground wires to IP / PMD. Check Harness. __Very good condition, just to make sure replaced PMD with new PMD and no change_______
3d] PMD Make: ___Standyne________
3e] PMD Age: ___Brand new__________
4] Stalling Issues
4a] Do you experience stalling only when hot? _____N/A__Truck never stalled_____
4b] Does it stall under particular circumstances? (ie hit bump, or on accel) __N/A____
4c] Does pouring cool water over the IP seem to help with restarting? ____N/A_____
4d] Is stalling momentary (engine recovers)? ____N/A_____
4e] Does SES light come on when engine hiccups? ___Yes______
4f] Does cruise control quit working when engine hiccups? ___Unknown________
4g] Does re-starting seem to reset engine, restoring cruise and power? ____Yes_____
4h] Changes to dash lights or instruments during stalling events? ____Just the check light when surging occurs_______
5] Running Issues
5a] On cold start, does upper rad hose get hard before engine warms up? ___N/A____
5b] Any bubbles or oil film in coolant overflow tank? ___N/A____
5c] Any white slime on oil surfaces (dipstick, CDR, oil Fill cap)? ____N/A______
5d] Excessive white smoke from exhaust on cold start? __N/A_______
5e] Excessive black smoke from exhaust under hard acceleration? ____N/A______
6] Performance Issues
6a] Do you have gauges? ___Yes________
6b] Maximum boost under load? ___Just under_14 psi________
6c] Have you added a performance PCM (reflash) or Chip? _____Yes_________
6d] Have you changed exhaust / downpipe / crossover? _______Yes_________
6e] Wastegate – mechanical or vacuum? ___Mechanical___________
7] Temperature-related Issues:
7a] Single or dual thermostats? ______Single______
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? ___Yes,Don’t remember what temp, but truck (when it was running)was solid @ 180 even under load, has never overheated _______
7f] (winter) Are you using a winter grille cover? ___N/A________
