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Old 03-05-2007, 05:42 PM   #1 (permalink)
93SierraDiesel
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6.2 Diesel stalling/hesitating

Hey guys, I finally got my '93 K2500 on the road about a week ago after taking forever to get it up and running, and I'm having some problems with the engine I'm hoping you all can shed some light on. The motor is all stock, non-turbo, and has a little over 100k on it. It had been sitting for a little over a year when I bought it and at that time I replaced on the engine:

Fuel Filter
Reman Injectors
Lift Pump (ac delco)
Front fuel lines from lift pump to engine
steel fuel injection lines

I replaced all the above and got the engine running well. No abnormal smoke. I ran it off and on until last week when I registered it. It had been running good (for the first few days driving it) up until 2 days ago when it would stall out when I would come to a stop. It would start running real rough and quit; although it would usually start back up pretty easily, sometimes had to crank quite a bit. Won't hold an idle, and sometimes had almost no power until I got up and going again and it would come back. It would do this after a minute or two of driving until at least 15 minutes of driving. Didn't matter temp wise, it was like it had to run for a certain amount of time before it would clear out- although last time I drove it, I didn't drive it long enough for it to clear out. Still never pukes smoke, it only smokes sort of bluish momentarily if you really goose the throttle.

Doing my homework, it seems that my trouble is fuel supply related, either I have a clogged fuel filter or the injection pump is going? It runs good off and on so the timing must be ok? The fuel filter is almost new, but maybe there was sediment in the tank, so I think I will try that first. Any ideas???? I'm afraid to drive it now. Thanks!
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Old 03-05-2007, 06:47 PM   #2 (permalink)
tigman
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Hi Welcom to the forum.

Fuel delivery related problem.
Do you still run on last year diesel?

When you start an engine with old fuel first you should drain the old fuel and fill it up fith fresh fuel and fuel conditioner.
If some residue was pull from your tank like algua they will clogyour filter werry fast.

Start again with fresh fuel with conditioner .inspect your fuel line for sign of fuel spill .

Next.
You can add a pressure gauge at the fuel filter exit to tell you if fuel lift pump still work

And instal a clear line on the return of the ip to know if ther is air bubble at the ip return

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Ed
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Old 03-05-2007, 07:12 PM   #3 (permalink)
93SierraDiesel
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Thanks! When I got the truck a few months back, it had maybe 1/8 tank of the old fuel. It ran off it, albeit not well. After I replaced all of the parts I put in conditioner at the same time with about 10 gallons of fresh fuel. It ran off this until I registered it, at which time I filled it all the way up with fresh diesel and conditioner. It's after it had a full tank that my problems started, I don't know if that stirred up the tank but the problems started about 75miles into the full tank.

I'll check flow at the return and the filter, hopefully it's nothing to do with the pump itself.
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1993 GMC Sierra 2500LD 4x4, 6.2 Diesel - DEAD 4/16/09 - Vortec TBI 5.7L Conversion Complete!
1997 GMC Sierra 2500HD 4x4, Vortec 7.4L, ECSB
2009 Pontiac G8 GT
1991 Olds Bravada 5.7L Vortec conversion
Various full-size Jeeps
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Old 03-05-2007, 09:58 PM   #4 (permalink)
High Sierra 2500
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Yep, it's a fuel supply problem. I think I'd start by changing the fuel filter... You never know what is in old fuel that could clog fuel filters. The other thing that could cause the problem would be an air leak. See the sticky on air leaks for instructions on how to find one...
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Old 03-07-2007, 11:52 PM   #5 (permalink)
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Update: I changed to another new fuel filter today, not at all better. The old filter (which was close to new) looked good and clean fuel poured from the outlet side with ease.

Tonight, I tried the air bleed procedure. I didn't see any air bubbles while bleeding, but afterwards it ran alot better. It would still gradually lose power and eventually stall after a couple miles, but after restarting it would run good again for another few miles. A big improvement, but not fixed. I tried to bleed it again just for laughs, and it didn't make a difference the second time. It's as if it slowly loses fuel pressure and dies, and then you restart and the cycle begins again. Still very sluggish.

I looked at the IP timing marks, and when viewed from the top of the engine looking towards the windshield, the pump is rotated slightly towards the passenger's side, maybe 1/8" from top dead center.

Any other thoughts? Still can't really drive it, but I seem to be making progress. Thanks!
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1993 GMC Sierra 2500LD 4x4, 6.2 Diesel - DEAD 4/16/09 - Vortec TBI 5.7L Conversion Complete!
1997 GMC Sierra 2500HD 4x4, Vortec 7.4L, ECSB
2009 Pontiac G8 GT
1991 Olds Bravada 5.7L Vortec conversion
Various full-size Jeeps
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Old 03-08-2007, 12:18 AM   #6 (permalink)
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what part of the country are you in sierradiesel?
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Old 03-08-2007, 08:30 AM   #7 (permalink)
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I'm in Connecticut.

Doing some more research, I'm wondering since I replaced the lift pump if maybe the oil pressure switch took a dump on me (it's the electric pump on this truck), and the lift pump is only working on the starting circuit???
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1993 GMC Sierra 2500LD 4x4, 6.2 Diesel - DEAD 4/16/09 - Vortec TBI 5.7L Conversion Complete!
1997 GMC Sierra 2500HD 4x4, Vortec 7.4L, ECSB
2009 Pontiac G8 GT
1991 Olds Bravada 5.7L Vortec conversion
Various full-size Jeeps
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Old 03-08-2007, 09:26 AM   #8 (permalink)
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wire in a test lite into the lead to the electric fuel pump and run the test wires into the cab and once you start it up you can see if you are getting power to the pump while going down the road or if the light flickers maybe bad wire/connector.
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84 chev k10 new crate 6.5 short box 4x4. 02 duramax 6speed stick excab vin#1GTHK291X2E188472. 84 mercedes 300d 5cylinder diesel 85 c10 6.2 suburban two wheel drive. 87 k20 6.2 four speed four wheel drive with a us gear two speed. 93 dodge cummins 3/4 ton 4x4 five speed. 01 toyota fourrunner 78 dodge 4x4 crewcab soon to be cummins powered and a stick. drove stickshifts all my life and am new member of the brotherhood of handshakers #82. number18 of the portland dp.
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Old 03-08-2007, 02:22 PM   #9 (permalink)
glentsup
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Definitely check out the electric lift pump, even if you have to pull the plug out and wire in 12v DC to it. The OPS (oil pressure switch) are known to fail as well. This is located on the left side on the engine real close to the firewall. You can check this switch out by putting an ohm meter on the male prongs (switch side) that go to the electric fuel pump. The vehicle has to be running to close the contacts on the switch. I had one fail as it ohmed out with high resistance (about 200 to 300 ohms). You could also try and jumper the female side of the connector that plugs into the OPS. It should be three connections so you need to find the two connections that control the electric pump. Also know there is a relay on the right side fire wall (engine side), underneath a removable plastic cover that controls the electric pump as well. Check that out too.

On the other hand if you are getting air in the system check all the feed and return fuel lines for leaks. Check the dribble back lines that are connected between the fuel injectors and especially the two injectors on each cylinder bank closest to the firewall. There will be a rubber plug on one side of each injector. I personally had a catastrophic failure one snowy day on the highway in regards to this. I replaced my pump and injectors and put some cheap rubber vacuum caps on the these two end injectors. Well as Murphy's Law would have it the diesel fuel ate through them and the truck stalled out. When I cranked it up it would run for a bit then stall. I put the correct rubber plugs in and tried to reprime the system only to find the electric lift pump crapped out. Once I replaced it and reprimed it was good to go. Good Luck!
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Old 03-12-2007, 03:54 PM   #10 (permalink)
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Ended up being that oil pressure switch! Runs 1000x better now, thanks for all the help.
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1993 GMC Sierra 2500LD 4x4, 6.2 Diesel - DEAD 4/16/09 - Vortec TBI 5.7L Conversion Complete!
1997 GMC Sierra 2500HD 4x4, Vortec 7.4L, ECSB
2009 Pontiac G8 GT
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Various full-size Jeeps
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