Problems...PMD maybe? Shutoffs, won't start, fuel leaks

[treegump]

For starters, got my south bend clutch installed and thought YES!! I HAVE MY TRUCK BACK!! Then I started smelling fuel and then the motor started shutting off randomly, and a few of those times I had to wait a bit to get it restarted. Just checked a few minutes ago and it'll crank, and fuel will come out the fuel filter manager, but it won't fire.

-1996
-K2500
-Standard
-205k
-relocated and another PMD (bought it off a supporter, but can't remember if the PMD was new...), injectors, glow plugs, FSOS, FTB, new OPS (which seems to be showing high since replacing it...), I'm sure there are others, just can't think of them
-"F" Turbo, no EGR
-Currently 30
-Power Service
-Merrillville, IN

General maintenance: inspect and evaluate the condition of each. When were they last changed?
- Air filter __< 100 miles ago_______
- Fuel filter __< 100 miles ago_______
- CDR Valve? ___~30k miles ago______
- Coolant – last flushed/replaced at ___<10k miles__________
- Oil – synthetic/regular, changed at __<7k (probably only 4k...but can't remember) & regular
- Batteries – state of charge, (matched set) replaced at _<10 miles____________
- Battery cables and grounds (removed, cleaned and tightened): I believe they are all cleaned & etc
- Glow Plugs - how many miles on them? _~30k (maybe??)____ What type? __**60 (the ones that automatically shut off - been a while)__
- Injectors - last changed at ___~30k____________


History: (Describe how the problem first appeared.)
- What were you doing when it happened? _Driving home - would only stall if idling or slowing down_____________
- How was the truck running fine before this problem appeared? _Running wonderfully___
- Has this problem ever happened before? __Not full turn off - did have some stalling/loss of power, but was still random___
- Describe any related factors that might be part of the problem. _I've never dropped the tank and check the fuel sock filter, cold weather, been sitting a while (but I ran through a tank of fuel after putting the new clutch in before it really started failing. Leaking fuel from fuel filter manager, heavy hits to the front when a skidsteer pulled me from a hole (maybe damaged PMD)__
- Have you checked for DTC (Diagnostic Trouble Codes)? (Y.N) _N (Check engine light never came on when it stalled)___ And? ________


Diagnostics:

1] Starting:
1a] Does the engine start? _not now________
1b] Does the engine crank over? ___yes_____
1c] Are your batteries fully charged? __yes_______
1d] Have you removed, cleaned, and tightened all battery connections? _no - engine cranks and did all the connections when I replaced the batteries_______
1e] Does your Wait to Start light come on for a time? How long? _normal - 5 clicks & 30 sec or something like that________
1f] Does your glow plug light come on? __Yes - same as the Wait to start...isn't it?_______ For how long? _________
1g] Do you see smoke from the exhaust while cranking? What color? _No smoke noticed_______
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? __Yes__________
2b] Do you get a steady flow of fuel from the water drain (T-handle) ? _(not sure - but was shooting 1-2' in the air from the fuel filter cap________
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? ___________
(will check 2c-2e when I get a chance)

3] PMD / IP Issues
3a] Location of PMD (on pump, on intake, remote mounted) _front bumper__________
3b] Condition of Extension harness (if used) Vendor or Homemade? __Vendor_______
3c] Condition of grounds / ground wires to IP / PMD. Check Harness. __Good, I believe_______
3d] PMD Make: ___________(Gotta check)
3e] PMD Age: _____________(Gotta check - but thinking <30k miles)

4] Stalling Issues
4a] Do you experience stalling only when hot? __Was, but has gotten worse_________
4b] Does it stall under particular circumstances? (ie hit bump, or on accel) _Deceleration & Idle_____
4c] Does pouring cool water over the IP seem to help with restarting? ___Didn't try it______
4d] Is stalling momentary (engine recovers)? __Used to be, but not any more_______
4e] Does SES light come on when engine hiccups? __Didn't notice it_______
4f] Does cruise control quit working when engine hiccups? __N/A_________
4g] Does re-starting seem to reset engine, restoring cruise and power? _N/A________
4h] Changes to dash lights or instruments during stalling events? _N/A__________

5] Running Issues
5a] On cold start, does upper rad hose get hard before engine warms up? _?______
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, EGT) ? __Boost & EGT_________
6b] Maximum boost under load? __0-12__________
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? __Single__________
7b] Have you replaced them lately? Manufacturer of replacements? _<30k________
7c] Have you pulled and cleaned Radiator and coolers lately? __Not recently__________
7d] Have you replaced the fan clutch? Manufacturer of replacement? _Can't remember_______
7e] (winter) Have you tested your antifreeze? Good to what temp? _Not recently, but seems like it was good for something like -50, haha_________
7f] (winter) Are you using a winter grille cover? ___No________


FFM is leaking. Drippage at heater (which is new) and then with pedal to floor, its leaking at sealing ring of the filter itself. FFM is also relocated to side of intake manifold.

Truck would randomly shut off while driving home. Though it might be the FSOS since I was leaking fuel on top of the block. Removed the intake manifold, replaced the FSOS & OPS, did the FTB mod & relocated to side of the instake manifold. Since then its still leaking, and the truck shut down randomly twice on the test drive of getting everything together. I went out today to get it started, and it wouldn't even fire. Just cranked...

 

[NVW]

If it's leaking fuel you could also be getting air in the fuel system. Get the leak fixed and see where you're at.

 

[great white]

So it was running fine, you changed a clutch and now it won't start?

If that is accurate, look over everything you touched and the surrounding area.

Look very, VERY closely.

It may be something as simple as a wire or fuel line you pinched in the bellhousing area.

I've done this myself and it's often a bear just to find it....

 

[treegump]

I started smelling fuel which led me to believe that I had pinched something near the bell housing, but there was fuel sitting on top of the block, and in further inspection, I could not feel any wetness on the fuel lines going down the backside of the block and around the bell housing, which is why I suspected the Ffm to begin with and that why I did ftb and relocated the manager. And when I did the ftb mod I replaced all the o-rings, hoses, clamps. It was stalling but recovering before I changed my clutch, and seemed to gradually get worse, but then my clutch went out and I parked it for almost 7-8 months... It never shut off randomly till about 350 miles after the new clutch was installed, and then it shut off 6 times on a 1/2 hr, 15 mile drive home. Shutting off on deceleration and idling.

 

[great white]

Smells like a PMD.......

 

[treegump]

I keep forgetting I left the original on the ip, so I'll unhook it from the extension and plug it in the stock and see what happens...

 

[WarWagon]

With fuel leaks you have an air problem. Put the clear hose on the IP return and solve the air problem 1st as per the GM manual. I would suggest a thread on fuel filter and ditch the leaky FFM to keep a FTB mod.

Even with a working lift pump the IP can draw a vac under specific conditions.

Have you checked the fuel for bugs after sitting for so long? Aka plugged sock in tank or worse...

 

[treegump]

Alright - unhooked the extension and got it plugged back into the pmd that was still mounted to the IP. While I was at it, I removed the FFM and cleaned it up and reinstalled it. Truck started right up after I bled it, but the FFM is still leaking. So next step is to remove the FTB modded FFM and install the stock FFM and see if that works. Also will look into getting another PMD. Did I see somewhere that one of our supporters offers a 5 yr warranty or something like that?

 

[NVW]

PMDCable offers a 7 yr. warranty for an extra charge, it does or did say 5 yrs. in his sig.

 

[great white]

Leroy has stated you can get a 7 year warranty if you pay for the right kit.

There's another non site vendor out there that also offers a 7 year warranty pmd kit.

IIRC, Leroy's costs a little bit less.

 

[treegump]

Thanks guys!

 

[treegump]

I went ahead and purchased Leroy's...I think, haha. Anyhow, 2 yr warranty, and the cheapest price I could find, so its all good. Re, relocated my PMD to the driver's side fender. Got to thinking, and the bumping and any debris that might get into the bumper (water/snow/dirt/etc) probably isn't good for it, so that's why I relocated it again. Appears to run great! Except in acceleration, the fuel gauge will go into E and the oil pressure will go way up which it didn't do until I replaced it. And the FTB FFM is still leaking from the top, even with a new standadyne filter with the rings. I am going to put the old FFM on and see if that works.

 

[JMJNet]

Assuming the notches are align properly, you can snug the ring with filter wrench for about 1/8 turn.

I know the age on mine causes it not to be tight with just my hand.
Probably, my hand is weaker also.

 

[treegump]

Would it be helpful to maybe put a thin bead of gasket maker around the inside corner of the housing - close to where the filter ring goes?

 

[Turbine Doc]

Would it be helpful to maybe put a thin bead of gasket maker around the inside corner of the housing - close to where the filter ring goes?

Not necessary new filter comes with a new gasket, that should seal it for you, is it possible the lock ring is cracked, sealant will be a band-aid if it works at all so don't try that you need to find/correct the leak.

Are you 100% sure the leak is coming from top of the bowl,, possibly from the center vent fitting? did you index the new element properly on the locating notch?

Also I suspect it is possible with so many mfrs going overseas sourcing that your new gasket could be bad as well, what brand filter did you install ?

 

[Brooklyn Tow]

If your ring is suspect, try to find a filter with the top head/ring attached, ( different style)......I think Baldwin makes them, it shouldn't be hard to find..........I'm sure plenty of guys run them.

It would rule out the OEM ring and/or the rubber gasket ring, on the regular filters.

JMO

 

[great white]

If you put the rings in the wrong way, it will leak like a SOB.

Should go together like so:

The metal ring serves two purposes. It gives the locking ring something to slide on so it doesn't bind the seal and it forces the seal evenly down and out against the sealing surfaces.

I bent the metal back up ring once and it leaked profusely. Had to take it all apart and "massage" it back into shape with a trim hammer....

 

[treegump]

I have all new o-rings everywhere and a new standadyne fuel filter with the rings pre-attached. I did take an oil filter wrench and tighten it up a bit and it stopped the leak. I sure hope that I have the wrench available to get it loose, cause I won't be able to do it by hand.

So...leak fixed (I believe), new PMD (will move it back to the front bumper), but now since I've replaced the OPS, my gauge is showing on average 65 lbs... Its at the 1:30 position (80?) when I first start it and at high idle...but previously with the old OPS it stayed at the 12 o'clock position. Any thoughts?

Also, there is a clicking noise coming from the rear end when I move from a dead stop. I'm thinking rear u-joint. When I installed the clutch I noticed that a cap on the u-joint was froze...so I'm thinking I just need to replace that. If I could afford it, I'd consider going to the high angle driveline - http://www.pirate4x4.com/tech/billavista/PR-1410_Yoke/ ...

 

[treegump]

Bump for the high oil pressure question and thoughts on the high angle driveline part.

 

[NVW]

I've changed OPS,s on a different brand of truck and had different readings.