MAGNUM SERVICES
Intelligence Guided By Experience
Problem: Explain your problem in concise language (ie: Cranks but won’t fire). Runs o.k.,then starts stumbling and eventually quits. Does not make a difference if it is hot or cold, rain or shine. After sitting a while it will start back, run fine, then start the symptoms all over again. ___________________________
Demographics: tell us about your truck and your ambient conditions:
- Year: _1996_____
- Truck model and class (ie: c2500) _2500 4X4 Ex. Cab 8600 G.V.W.________
- Automatic or Standard _4L80E replaced 6/14/07 with GM Reman., Transfer Case replaced 10/2000.________
- Mileage: (indicate miles or km) _140,681 Miles BUT that is questionable as it was built in Canada with the "Metric" dash and now has the "English" dash________
- Replaced parts and mods (IP, PMD, chip/PCM, TM, injectors etc)Oil Pressure Switch on 12/11/08, Replacing it again on 5/16 or 5/17/09.. Lift Pump on 1/28/09 from Autozone replaced under warranty..PMD yesterday 5/15/09 with New style Stanadyne with # 9 Resistor replaced under warranty, I know you hate Stanadyne and prefer the D-Tech type but as stated replaced under warranty.. IP replaced with rebuilt pump 7/11/07 at 127,162 Miles. Rebuilt Injectors about three Years ago. PMD,Pump,Injectors all purchased from Diesel Injection Service in Cincinnati,Oh. # 9 Resistor up graded from a #6 resistor on 5/15/09 purchased from SS Diesel along with Heatsink.__________
- Model: ‘S’ or ‘F’ engine, NA or Turbo, EGR? ___"F" Turbo___________
- Ambient outside temp: (indicate *C or *F) 5/16/09 65 F right now,Yesterday 5/15/09 75 F ________
- 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 and Power Service Diesel Kleen ALL year round__________
- Where are you located? Covington, Ky. ten miles south of Cincinnati,Oh. _____________
General maintenance: inspect and evaluate the condition of each. When were they last changed?
- Air filter 1/05/09_________
- Fuel filter 1/05/09_________
- CDR Valve? Unknown What is the CDR Valve? _________
- Coolant – last flushed/replaced at _1/08____________
- Oil – synthetic/regular, changed at 1/05/09 Shell Rotella 15W40 Regular ___________
- Batteries – state of charge, (matched set) replaced at Fully charged Duralast Gold Replaced 8/06/08.. Matched set._____________
- Battery cables and grounds (removed, cleaned and tightened): All new cable ends cleaned and replaced 1/05/09, Starter replaced 5/18/07.. Alternator replaced 1/02_____________
- Glow Plugs - how many miles on them? Replaced 12/30/08.. 3000 miles ago._________ What type? _SS Diesel Quick heat with new controller and new wire ends.____________
- Injectors - last changed at _Three plus years ago.______________
History: (Describe how the problem first appeared.)
- What were you doing when it happened? _Plowing snow in end of 1/09, 10 F outside temp., Loaded with Salt and 800# snow plow. Truck was running fine and started losing power/stalling/hard starting,replaced fuel filter, same problem.. No noise from Lift Pump so replaced it under warranty, still no power/stalling/hard starting, replaced PMD with "old style" Stanadyne unit. Truck ran great until 5/13/09 then ALL the same problems started again while pulling enclosed 7x16 trailer loaded with Lawncare equipment and also while driving without trailer._____________
- How was the truck running fine before this problem appeared? Great____________
- Has this problem ever happened before? Years ago and replaced IP on 7/11/07_______________________
- Describe any related factors that might be part of the problem. None_____________
- Have you checked for DTC (Diagnostic Trouble Codes)? (Y.N) _Y___ And? _NO Codes_______
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? _Flashes through it's cycle________
1f] Does your glow plug light come on? Isn't this the same question as above? ________ For how long? _________
1g] Do you see smoke from the exhaust while cranking? What color? Never noticed________
2] Fuel Issues (if not running):
2a] Can you hear your lift pump working? Sometimes____________
2b] Do you get a steady flow of fuel from the water drain (T-handle) ? Yes when I hear the Lift Pump running_________
2c] Loosen the inlet line from the IP – is fuel coming out (Lift Pump on)? Yes when I hear the Lift Pump running.__________
2d] Loosen an injector line and crank the engine - does fuel come out? Have NOT checked_________
2e] Do you hear a vacuum (hiss) when you remove the fuel cap? Yes___________
3] PMD / IP Issues
3a] Location of PMD (on pump, on intake, remote mounted) NOW located on a SS Diesel Heat sink installed 1/16/09 on side of intake but when the 6 ft. cable arrives it will be re located under the front bumper.__________
3b] Condition of Extension harness (if used) Vendor or Homemade? New from Stanadyne.. Waiting on 6 ft. cable from PMD Cables after end is changed for "new style" Stanadyne PMD _________
3c] Condition of grounds / ground wires to IP / PMD. Check Harness. Clean,tight_________
3d] PMD Make: Stanadyne "new style"___________
3e] PMD Age: Replaced under warranty 5/14/09_____________
4] Stalling Issues
4a] Do you experience stalling only when hot? No____________
4b] Does it stall under particular circumstances? (ie hit bump, or on accel) _On acceleration_____
4c] Does pouring cool water over the IP seem to help with restarting? It did until replaced on 5/14/09_________
4d] Is stalling momentary (engine recovers)? After sitting a while_________
4e] Does SES light come on when engine hiccups? NO_________
4f] Does cruise control quit working when engine hiccups? Unknown___________
4g] Does re-starting seem to reset engine, restoring cruise and power? After it sits a while________
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? Never checked_______
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? _Factory__________
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 a few years back from the local Chev. Dealership________________
6e] Wastegate – mechanical or vacuum? Vacuum with controller replaced about two years ago______________
7] Temperature-related Issues:
7a] Single or dual thermostats? Single____________
7b] Have you replaced them lately? Manufacturer of replacements? _Two years ago ________
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.. to -45 f_________
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 have owned this truck since 2000 and replaced the IP twice, the last one on 7/11/07 and has been mostly reliable in ALL weather,loaded or empty,and would like to keep it BUT this recurring problem makes me want to junk it. __ANY and ALL replies will be GREATLY appreciated, Keith_______________________________
__________________
Demographics: tell us about your truck and your ambient conditions:
- Year: _1996_____
- Truck model and class (ie: c2500) _2500 4X4 Ex. Cab 8600 G.V.W.________
- Automatic or Standard _4L80E replaced 6/14/07 with GM Reman., Transfer Case replaced 10/2000.________
- Mileage: (indicate miles or km) _140,681 Miles BUT that is questionable as it was built in Canada with the "Metric" dash and now has the "English" dash________
- Replaced parts and mods (IP, PMD, chip/PCM, TM, injectors etc)Oil Pressure Switch on 12/11/08, Replacing it again on 5/16 or 5/17/09.. Lift Pump on 1/28/09 from Autozone replaced under warranty..PMD yesterday 5/15/09 with New style Stanadyne with # 9 Resistor replaced under warranty, I know you hate Stanadyne and prefer the D-Tech type but as stated replaced under warranty.. IP replaced with rebuilt pump 7/11/07 at 127,162 Miles. Rebuilt Injectors about three Years ago. PMD,Pump,Injectors all purchased from Diesel Injection Service in Cincinnati,Oh. # 9 Resistor up graded from a #6 resistor on 5/15/09 purchased from SS Diesel along with Heatsink.__________
- Model: ‘S’ or ‘F’ engine, NA or Turbo, EGR? ___"F" Turbo___________
- Ambient outside temp: (indicate *C or *F) 5/16/09 65 F right now,Yesterday 5/15/09 75 F ________
- 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 and Power Service Diesel Kleen ALL year round__________
- Where are you located? Covington, Ky. ten miles south of Cincinnati,Oh. _____________
General maintenance: inspect and evaluate the condition of each. When were they last changed?
- Air filter 1/05/09_________
- Fuel filter 1/05/09_________
- CDR Valve? Unknown What is the CDR Valve? _________
- Coolant – last flushed/replaced at _1/08____________
- Oil – synthetic/regular, changed at 1/05/09 Shell Rotella 15W40 Regular ___________
- Batteries – state of charge, (matched set) replaced at Fully charged Duralast Gold Replaced 8/06/08.. Matched set._____________
- Battery cables and grounds (removed, cleaned and tightened): All new cable ends cleaned and replaced 1/05/09, Starter replaced 5/18/07.. Alternator replaced 1/02_____________
- Glow Plugs - how many miles on them? Replaced 12/30/08.. 3000 miles ago._________ What type? _SS Diesel Quick heat with new controller and new wire ends.____________
- Injectors - last changed at _Three plus years ago.______________
History: (Describe how the problem first appeared.)
- What were you doing when it happened? _Plowing snow in end of 1/09, 10 F outside temp., Loaded with Salt and 800# snow plow. Truck was running fine and started losing power/stalling/hard starting,replaced fuel filter, same problem.. No noise from Lift Pump so replaced it under warranty, still no power/stalling/hard starting, replaced PMD with "old style" Stanadyne unit. Truck ran great until 5/13/09 then ALL the same problems started again while pulling enclosed 7x16 trailer loaded with Lawncare equipment and also while driving without trailer._____________
- How was the truck running fine before this problem appeared? Great____________
- Has this problem ever happened before? Years ago and replaced IP on 7/11/07_______________________
- Describe any related factors that might be part of the problem. None_____________
- Have you checked for DTC (Diagnostic Trouble Codes)? (Y.N) _Y___ And? _NO Codes_______
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? _Flashes through it's cycle________
1f] Does your glow plug light come on? Isn't this the same question as above? ________ For how long? _________
1g] Do you see smoke from the exhaust while cranking? What color? Never noticed________
2] Fuel Issues (if not running):
2a] Can you hear your lift pump working? Sometimes____________
2b] Do you get a steady flow of fuel from the water drain (T-handle) ? Yes when I hear the Lift Pump running_________
2c] Loosen the inlet line from the IP – is fuel coming out (Lift Pump on)? Yes when I hear the Lift Pump running.__________
2d] Loosen an injector line and crank the engine - does fuel come out? Have NOT checked_________
2e] Do you hear a vacuum (hiss) when you remove the fuel cap? Yes___________
3] PMD / IP Issues
3a] Location of PMD (on pump, on intake, remote mounted) NOW located on a SS Diesel Heat sink installed 1/16/09 on side of intake but when the 6 ft. cable arrives it will be re located under the front bumper.__________
3b] Condition of Extension harness (if used) Vendor or Homemade? New from Stanadyne.. Waiting on 6 ft. cable from PMD Cables after end is changed for "new style" Stanadyne PMD _________
3c] Condition of grounds / ground wires to IP / PMD. Check Harness. Clean,tight_________
3d] PMD Make: Stanadyne "new style"___________
3e] PMD Age: Replaced under warranty 5/14/09_____________
4] Stalling Issues
4a] Do you experience stalling only when hot? No____________
4b] Does it stall under particular circumstances? (ie hit bump, or on accel) _On acceleration_____
4c] Does pouring cool water over the IP seem to help with restarting? It did until replaced on 5/14/09_________
4d] Is stalling momentary (engine recovers)? After sitting a while_________
4e] Does SES light come on when engine hiccups? NO_________
4f] Does cruise control quit working when engine hiccups? Unknown___________
4g] Does re-starting seem to reset engine, restoring cruise and power? After it sits a while________
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? Never checked_______
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? _Factory__________
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 a few years back from the local Chev. Dealership________________
6e] Wastegate – mechanical or vacuum? Vacuum with controller replaced about two years ago______________
7] Temperature-related Issues:
7a] Single or dual thermostats? Single____________
7b] Have you replaced them lately? Manufacturer of replacements? _Two years ago ________
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.. to -45 f_________
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 have owned this truck since 2000 and replaced the IP twice, the last one on 7/11/07 and has been mostly reliable in ALL weather,loaded or empty,and would like to keep it BUT this recurring problem makes me want to junk it. __ANY and ALL replies will be GREATLY appreciated, Keith_______________________________
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