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Swapping broken 6.2 for newer 6.2

What is the fuel pressure at the filter? Or do you have a mechanical pump? I lost that in the discussion.

Sounds like air. And no taking foot off throttle will stall with air in the system.

What is the battery voltage? Have a volt meter on the dash to see if the alt starts working when you get it running. I assume you have a charger on the batts?
 
I believe I have a mechanical pump because there is no gauge anywhere to tell me the pressure. Is the pump the thing at the bottom driver side of motor with the fuel lines going to it?

The alt. works but I don't think it charges above 11v or 12v. So I think it will need to be changed here pretty soon. Yes I do have a charger, I've been charging the battery that hooks to the starter almost the whole time.
 
Take the fuel line that goes to the IP off at the filter. Splice in about 2-3 ft of clear tubing(home depot, hardware store etc). Purge the line as best you can and run the truck and see if there are air bubbles in the fuel. There should be NONE. If there is then you are sucking air somewhere. You can run the truck off a 5 gal can of fuel. when I am in doubt of the fuel system on a diesel I usually grab a cheap electric fuel pump and hook it right to the IP and run the other side to a 5 gal can of fuel. That elimintes all the ful lines on the truck. if it runs good then there is a problem with thelines/tank on the truck.
 
I did notice a couple of the injectors were leaking fuel while the motors on. I tried to tighten them up but they were already pretty tight, but I manged to get a few more turns out of them.But I haven't had a chance to see if they were still leaking or not. If so, could air leak in from them? Also, does that mean their crossthreaded?
 
OK, I have an extra set perhaps I'll start there and switch them if their still leaking. If not I'll do the sightglass thing.
 
Boyces said they did a test run on the motor before shipping, they said they hook them up to radiators and make sure they don't leak or anything like that. But I guess it's apparent I have a problem with the fuel system right? The guy I bought my IP from said he checks injectors for free though so maybe if the injector lines don't do the trick I can do that. I'm kinda leaning towards the lines though because they were pretty tight but still leaking. But I'm by far an expert at this so my cents isn't worth much.
 
Your return lines could be leaking too.

When the engine starts will it stay steady at 2000 RPM? I am thinking that the idle may be set too low or metering valve in the injection pump may be sticking. If it isn't a line leak as suggested above.
 
RNation said:
Boyces said they did a test run on the motor before shipping, they said they hook them up to radiators and make sure they don't leak or anything like that. But I guess it's apparent I have a problem with the fuel system right? The guy I bought my IP from said he checks injectors for free though so maybe if the injector lines don't do the trick I can do that. I'm kinda leaning towards the lines though because they were pretty tight but still leaking. But I'm by far an expert at this so my cents isn't worth much.
Click to expand...

It's rare but I have seen them crack right where the flare meets the line.
 
I don't have an RPM gauge to tell. The IP isn't that old though, it's probably about 4 months or 10-15,000 miles old. Also it was on the old motor I had back when it worked, and it ran fine then. But I guess that doesn't mean it can't happen so soon.
 
I got the injector lines switched out but while I was bleeding the lines I ran into another little setback. The positive side of the battery started smoking and when I got to it the starter wire, other positive wire from other battery and a couple washers had been "tack" welded together. I guess the connection wasn't tight enough and the sparks were hot enough to weld the wires together. Problem is it won't tighten anymore so I have to get that taken care of first.

On another note, before I switched the injector lines I started her up and about 15 seconds before she died smoke started coming out of this thing in the picture. It was coming out of the hose connector underneath it, I accidentally ripped it when doing something. I switched the rubber connector part with another one I had so that's fixed but I didn't think smoke should be coming out of it since it's connected with the intake I thought it should suck air in. Any thoughts on that?
 
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The tuna can looking thing ? That is your CDR. It's kinda like a really big PCV for diesels. How careful were you when swapping IP and INjs ? If you got ANY dirt in there you may have an issue.
 
I only swapped the IP, I left the injector lines and injectors on it. It was a pretty clean job though, I took it off the other motor and right on the newer one.

The truck runs fine when it starts. It idles fine and sounds fine, but I haven't checked the smoke though. I can do that in the morning.

So the CDR can let pressure out then? The acronyms page says it's a crankcase depression regulator. I just thought that was weird that it's on the intake that sucks air but this thing relieves air.

I got some bad luck with all this stuff. I just had to take my angle grinder and cut them battery wires and bolt apart. And the damn battery port is stripped. It's got a threaded female insert instead of the post. I suppose I could try a bigger bolt and maybe re thread it since the battery sides only lead, it might soft enough.
 
I hate side post batts. I changed over to top. How exactly did you get the IP out without removing the lines and please don't tell me you bent them out of the way....
 
Ya I bent them out of the way, but they didn't really bend. That's how the guy I bought my IP from told me how to do it. Is that bad?
 
Very bad. There is a coating inside the lines that breaks loose and probably clogged your injectors. You can bend them very slightly but it is NOT recommneded. My suggestion would be to pull the injs and have them tested or used the ones off the old motor and use the lines off the old motor(Which ever set of lines you did not bend are the ones to use) I would be very suspicoius at this point of debris in the injs or the lines screwed up. NEVER bend them to do an IP job. Whoever told you that is a moron.
 
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