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sputtering and stalling, ideas please

T

tumuch

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P.G.B.C. Canada
my 6.5 started sputtering, blowing smoke and stalling this morning heading to work..Im about 8hrs away from home in alberta so its a little stressfull..I am getting codes 18,35,54,91,94 I was thinking ecm failure..I have koso tune chip and a-team turbo, larger exhaust, newer plugs and injectors Its a 95 1ton..its been running great untill this morning..I was getting a surging of the throttle when I let off as well. it seems to run well then kicks in with stuttering, blowing black smoke and dies, any ideas for me besides crying about it??
 
Sounds like a fuel issue. I believe the codes you listed are for obd1 so also could be an OPS issue. If you have a pressure gauge check fuel pressure . if not open the drain T while running see if it has good flow. Caution if you don't get any fuel the engine will die and be hard to start until you fix the issue. I'd make sure I was somewhere I could get parts before testing.
 
OPS runs LP when engine is running unless you have added a relay.

If you know for sure that LP is running when engine is running.
Then try a KNOWN WORKING PMD.

Make sure both batteries are good also.
You may want to load test them one at a time.
 
Thanks for the response.....I have tested the lp, open the drain while running it flows good, I have a new delco ops installed with a relay to. I changed the fuel filter and cleaned the housing good, I am suspecting the pmd as well, i have a bumper mounted one.. I dont believe its a fuel issue now, i know the pmd still on my pump is no good, so kind of wondering if the surging and stuttering could be pmd related before ordering a new one. I believe its a electrical issue..anyone in fox creek alberta have a pmd to do some testing
 
Both batteries are good, they are new last yr and have a new alternator as of 4 weeks ago, not a rebuilt a new wilson alternator,
 
Try unplugging the OS on the IPand then try to start it. It will take a lot of cranking to get it started. If it runs better but with less power the OS is bad. If it is unchanged or worse try unplugging the CPS and restarting.
 
Bad PMD can cause anything from stalling, sputtering, surging, no cruise control, shutting down in the middle of nowhere.

Unfortunately, nobody really know how to test it other than putting a KNOWN WORKING PMD that is known to work to start in your truck.
Notice, it does not have to be new but if you don't have one that you can test when the truck was running good, that means you probably want to get a new one.

Leroy have on sale so check with him.

He is a great vendor with great service because his name is on the line in this forum.
 
is there still a filter harness installed on the Optical sensor harness? (its a short length of wire with a little black cube bonded to the wires) it may be bad and be causing issue. it can be removed and harness plugged directly into the OS.

We bought a 98 that was running weird with lots of stuttering, and unfortunately I never found out what exactly fixed it, as I changed a few things at once and it ran great after that. it was either the new PMD or the filter harness delete. :)

Have you cleaned your grounds?

Finally, fill out your signature so we can help you as much as we can.

Good luck!
 
Thanks for the replys..I have ordered a new pmd..after watching a # of videos of there failure I believe its my problem..it starts and runs fine then cuts out spiratically..im working 14 hr days and dont have time for much..had to rent a truck and hope my truck can get me and my gear home in a week..this is my second engine I installed..all my grounds are tight. Batteries good. Battery post modded. Every mod jist about done on it.I have done it all myself so know its all tight..will post back if pmd fixes it..might fill a signature when time permits...tjanks guys
 
Do you have a Chinese PMD extension cable or a expensive made in USA cable? The China cables are known to fail and cause bad PMD symptoms.

A wiggle test on the PMD cable is useful. AKA does the engine stall when wiggling the cable?
 
So the new pmd cured the spuratic revving..about 4hrs into my drive home it started sputtering and dieing so i found to stop for a few minutes and start it again it would go ok for a bit and die again, this was on a bit under a half tank, then it got worse under a quarter tank but would still go. I stopped and filled it up and it ran great so i think the tank pickup must be damaged. How do people test lp pressure, it seems like a good flow when the drain valve is opened.
 
Clear line off IP to return rail. Look for air bubbles when stalling. Pinhole leaks on pickup assy are common. Restricted tank sock can also be an issue.

Otherwise use a pressure/vac gauge off the water drain.
 
Hello, so i just got it home and parked it ...time to get it fixed now..I replaced the lift pump just to be sure, new pmd. So I unplug the optical sensor and it runs good with less power..After clearing the codes I had 35,91.unplugging optical sensor gives me 17 to..ready to order a new injector pump but suspecting my optical sensor is the problem..opinions,advice ideas please before i order another part.
 
I pulled the intake off to tò check for any leaks..found my filter manager was leaking out of the bottom heater element, i replaced the defective element and fixed the leak..made no difference to the problem
 
Is the PMD you ordered new?

You have to check all the leaks and fixed them.
If the bottom heater of FFM is leaking, what else can be leaking?
Did you change the hoses around FFM also?
 
New pmd, fixed the leak on the fuel manager, no other leaks , new hoses to and from the filter manager, I just swaped the optical sensor from a working injector pump, it made no difference, doing the same thing, engine light comes on under acceleration. Guess I should drop the tank and take a look.
 
To verify your not sucking in air, replace the fuel return line coming out of the IP. It is 1/4" diameter, and about 5-6" long. Run it and watch for bubbles.

What is your fuel pressure going into the IP?

IF you want to drop the tank, it doesn't hurt. Unless you create a new leak/vacuum point.
 
If code 35 won't clear it means it is still a current problem. Did you replace the PMD extension harness as well as the PMD? Did you clean the grounds including the ground on top of the IP?

Is the new PMD on a heatsink and mounted where? It will quickly burn up without a heatsink so just in case you ran the PMD without a heatsink...

Code 35 = PMD issues from this site:

http://www.accuratediesel.com/pmd_list.html
 
Yeah 35 is very common with a bad PMD.

A lot of the time a fuel delivery problem won't kill the engine, just makes it run sluggish. Most times if the engine dies due to fuel delivery its because air is getting in (not always) the system.
If you find you have a dirty tank sock consider removing it and installing a frame mounted spin on LP prefilter.
 
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