1994 6.5TD intermittent shut off, any Ideas? - Diesel Place : Chevrolet and GMC Diesel Truck Forums
 
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Old 04-23-2013, 08:45 PM   #1 (permalink)
rebelscout
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1994 6.5TD intermittent shut off, any Ideas?

We have a 1994 K2500 suburban with the 6.5TD and now it wont start. For a while it would start just fine, run just fine, and then intermittently shut down just as if you turned the key off.. Most of the time it would start back up and run fine for a while. Every once in a while you would get a quick (off/on) like stumble and keep on truckin. Back over the winter while changing ball joints etc, (wow what a fun job ) I happened upon a problem that seemed to fix my issue for a while.. I noticed the passenger side battery cable was rubbing through against the corner of the inner fender well and was grounding there.. I fixed that issue and things were fine for a while, but now its back.. Some more history,
Ive replaced the lift pump, OPS (BWD brand), and Stanadyne (grey) PMD a couple years ago, and put a relocator kit on it with heat sink this past winter, mounted behind the bumper.
Now the things I know as of this evening.
turn key on and crank the engine, I can feel the lift pump pulsing. You can cycle key, and every once in a while it will start and run great for a few seconds and shut off cleanly.. Some times you cant get it to start at all! Im in a very rural area, and good (or any) 6.5 diesel mechanics are hard to find.. Id love to hear any Ideas before I start throwing money I dont have at it
Sorry for the long winded post
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Old 04-23-2013, 11:09 PM   #2 (permalink)
Freddyack
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Couple of thoughts:

I just did a quick search on the forum. Found this thread which kinda sounds like what you are going through: http://www.dieselplace.com/forum/63-...on-switch.html

Could also be bad grounds. Are all of your grounds clean? Not just at the batteries but also where they attach to the block and from the block to the frame. I just cleaned mine up (I thought), but am learning I missed a few so back at it this weekend.

Also, is your fuel filter fresh and have you done the lift pump test? http://www.dieselplace.com/forum/63-...tart-here.html. Just want to eliminate fuel flow as a problem. Jut because the lift pump makes noise doesnt mean it is pushing fuel. BTW, you should do this mod (our '94's need it): http://www.dieselplace.com/forum/63-...y-install.html
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1994 Suburban K2500 4X4, 280,XXX Miles & Counting...
Lubrication Specialist Oil Cooler & Lines
4 in Exhaust & K47 Intake System
Boost and Transmission Temp Gauges
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Dmax Fan & Hayden HD Fan Clutch
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Old 04-23-2013, 11:45 PM   #3 (permalink)
jerrey
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Your symptoms sound like the PMD is going/gone bad again if it is more then two years since being replaced I would get a PMD that you know is functioning good and test see if the issues are resolved by it. The relocation setups are good they help but they are no guarantee of longevity. My truck basically devours a PMD every 12 to 14 months even with the heat sink for the PMD being in the cold air in front of the engine compartment. You should have a backup one on hand at all times anyway get a different PMD eliminate it as the cause of your issues and if not then throw it in the glove box as a back up.
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98 Chevy 2500 6.5 (F code)
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home made waste gate controller,
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2.5 mandrel bent cross over,
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Old 04-24-2013, 10:46 AM   #4 (permalink)
JMJNet
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Let me get it straight, the PMD was originally inside the hood and now put on a heatsink outside the hood? If so, I agree with jerrey that it may fail again.

You have to do the Lift Pump test as suggested.
We cannot say that since part is new, therefore, it does not go bad???
With most part build cheaply overseas or even our neighbor to the south, QC is almost non-existent. So everytime there is trouble, all the trouble shooting tests have to be done.

No matter where you are, there is never any competent 6.5L Diesel mechanics nearby.
You just have to learn it yourself, that is why forum like this is useful.
One thing, though, you need to do the work yourself by becoming eyes, ears, hands, etc. We are not psychic that can pin point the trouble spot. All we can do is give suggestions. Reading the FAQ is always recommended and at the end of the day, you will probably become more competent than any mechanics at least for the 6.5L diesel (don't assume that other diesel is the same, they are not).
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Bosch Duraterm GP
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Last edited by JMJNet; 04-24-2013 at 10:46 AM.
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Old 04-24-2013, 11:40 AM   #5 (permalink)
Veg_Out
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To JMJ's point. Almost everytime I troubleshoot anything anymore...I look to the newest part I replaced. New parts are crapola.
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Old 04-27-2013, 11:19 PM   #6 (permalink)
rebelscout
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Thanks for the thoughts & suggestions, still working on it

getting ready to bite the bullet and buy another grey PMD.. This is what Ive done so far:
Replaced the ignition switch since ot was only $15 and an easy problem elimination tactic, but didnt fix it. I looked over the grounds and everything looks good with the exception that the one on the upper/back pass side of the block is oily @the frame . With the engine idling, the fuel T- valve pours a stream of fuel when I open it up, so lift pump must be working. I had a new crank/position/sensor ordered the other day, but thought to myself that if this was the problem, it would surely be sending a code? I have not replaced it yet.
THIS IS WHAT HAPPENED THE OTHER DAY:
Truck starts just fine and runs/idles just fine for several (10-15) min then shuts off like you turned the key off. Progressively the run times get shorter and shorter and restarts become more eratic (wont start on first crank, cycle key, try again) untill truck just eont srart at all.
TODAY:
I went to put in the CPS and started the truck. Truck idled/ran fine for about 10the min or so and stalled. A restart ran for 20the min or more, so I tried to drive the truck home. I only had 2 stalls and then the rest of the 6 miles home was flawless. Cant quite understand it. I wish I was getting codes.
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Old 04-27-2013, 11:49 PM   #7 (permalink)
Freddyack
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This is a shot in the dark, but have you tried unplugging the fuel shut off solenoid? it is located on the IP, about the diameter of a $0.25 with wire(s) coming out of it.

From what I've read the fuel shut off solenoid serves no useful purpose so it cant really hurt anything to try.
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Lots of problem solving information in the 6.5L FAQs 6.5L Parts List Here

1994 Suburban K2500 4X4, 280,XXX Miles & Counting...
Lubrication Specialist Oil Cooler & Lines
4 in Exhaust & K47 Intake System
Boost and Transmission Temp Gauges
Feed The Beast Mod
Dmax Fan & Hayden HD Fan Clutch
Heated, Powered Towing Mirrors

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Old 04-28-2013, 01:45 AM   #8 (permalink)
VanBoy
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If you haven't, pull your PMD and check the bolts that hold it down to the heat sink. Also, unplug the wiring and check for any corrosion on the pins/plug for the PMD end. Check to see if the wire harness has rubbed on anything (never know). Did you use the silicon pan or heat past to mount the PMD to the heat sink originally?

If you want, you could get a Dorman PMD. Has a lifetime warranty and they sell it on Amazon. Look for the lowest price listed there (last I saw, you could find one for about $175 or less). You can also buy the same Dorman PMD at the local parts stores (NAPA, Carquest, O'Reily). As stated, PMD's die....it's just a matter of WHEN. Some can get 24 months to 36 months out of them. A few, can get longer (granted, who knows if the rig is a daily driver vs occasional driver).

When you get your issues solved (if it's PMD or other), I suggest, as others have, to get a spare. There are a bunch of "good used" being sold on Ebay for less then $100 (sometimes under $60). All you have to do is drive the heck out of the truck for the "warranty period" (some 1 month, some 2) to make sure it works. I have two spares mounted on a heat sink ready to be used in case (simply unmount the old unit, unplug, plug in new....start and remount).

My only issue w/ the PMD right now on mine, is sometimes when it's wet (rain), it seems like it want's to stumble for a bit. But when dry, all is fine. Had one stalling once, but who knows why.....hasn't happened again. And I'm running a D-Tech no warranty that I bought off Ebay.....replaced it Jan this year. So far, so good.....

Good luck.
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1999 Ford E-350 7.3L Power Stroke Club Wagon, 3.55
1990 Ford E-350 7.3L IDI Club Wagon, 3.54LS x2
1994 Chevrolet C2500 6.5L TD, 3.42
1981 VW Rabbit Pickup 1.6L N/A x2
1978 VW Rabbit 1.5L N/A
1977 KW K100 NTC-350, twin screw semi
1977 IH Transtar II NTC-290 single axle semi / IH Transtar II NTC-290 twin screw semi
================================================== ==
Stanadyne PMD installed 6/13 replaced- reinstalled D-Tech ,Soot Trap Delete Jan 18, 2014 / Heath TurboMaster Dec 22, 2013 / New OPS (BWD), OPS Relay mod,
black Stanadyne PMD w/ #5-June 2013 / Dorman relocation kit, D-Tech PMD to bumper, #9 resistor- Jan 2013 / Carter Lift Pump, P74143 10-15psi, 32gph- Dec 2012 / Brought home Dec 17, 2012

Other then that, the Chevy is STOCK.
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Old 04-28-2013, 11:08 AM   #9 (permalink)
FloridaHorseman
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This is a classic PMD failure scenario. As stated, 94' and up 6.5 owners should always carry a spare known-to-be-working PMD and convert IP mounted PMD's to a quality extension harness and remote heat sink. And I am also of the opinion since fuel supply issues (LP/OPS failures and clogged fuel tank socks) also plague these trucks a permanently installed fuel pressure gauge mounted where it can be monitored while driving is also a necessity. ~FH
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Old 05-30-2013, 02:08 PM   #10 (permalink)
rebelscout
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Folks, thanks for all the input. It ended up being the PMD. I had replaced it once (grey stanadyne) in a pinch and mounted it under the hood, and then later purchased a remote kit with heat sink from a seller on Ebay. Not sure how to tell if the remote kit is quality or not?
The dealer I purchased the PMD from suggested that I install it back on the pump, but I ended up putting it on the heat sink and bolted it behind the bumper. I live an a rural area (southeast Missouri Ozarks) and stream crossings are an occasional thing.. Should I be worrying about water splashing on the PMD every once in a while?
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