My truck broke today. I was going up a hill and I had no power whatsoever. Put it to the floor but there was nothing. Pulled over and took a look. I'm no mechanic but I could tell something was wrong by the cascade of fuel pouring out from beneath my truck. It was draining down about where the transmissions mates to the engine. It looked like it was happening before the fuel filter as that was dry and after the pump because it was really coming out. When I told AAA about it they sent the fire department because of a fuel spill. Since it was less than 50 gallons, they didn't do anything. Good thing, I didn't want to be on the news as a hazardous materials spill.

Anyway, as I sit here and wait for the dealer to call, I was wondering what could have broken. Any ideas?

Thanks

Ryan

2002 2500HD D/A EC LB

Could be an injector leaking fuel into the crankcase, filling the crankcase and thats what is causing the leak. Also could be a leak at one of the HP lines, specifically one that would go from the rail to the injector. Could be a leaking FRP sensor. Regardless, it wont be hard to find if leaking that bad.

Actually it's worse. Just found out that there's a hole burned through the back cylinder on the right side. Fuel was shooting through the hole. So far they say they got to replace the head and piston. They won't know what else until they tear it down. They just scoped it so far.

Luckily, it's under warranty.

Yee ikes!

I wonder how that happened?? http://www.dieselplace.com/forum/images/smilies/confused.gif

Huh?

:eek: :confused:

Almost sounds like high pressure cutting!!!! 26,000 PSI if the stream is tight enough will cut through anything!! :(

One in a hundred thousand I bet!

Holy Censored batman. :eek:

Keep us informed, Ryan. Lots of people will be interested in hearing the official story of this.

Ryan,

Would you please provide us some details on the truck: Year, miles, and did you have an EGT gauge, and if so, what kind of temps was it showing.

Glad to hear it is still under warranty. That could be an expense repair.

Thanks.

The better pull both heads and see what the other side looks like too. That just can't be good...

It's a 2002 with the Allison. I just turned 70,000 miles on it. 0 engine problems previously.

It has EGT and boost gauges. I was going up a hill on the highway and noticed a lack of power. I floored it and nothing good really happened. RPMs went up to 2500 but there wasn't any power. First I thought it was my transmission. I looked at my gauges. EGTs were not high, well under 1000, sorry can't give a precise number, boost was nothing. That's when I pulled over and found diesel fuel pouring out of the engine.

I'll post more when the dealer finds out more.

Here's the latest from the dealer. It's not a hole in the header or anything like that. I wish they'd make up their minds. The high pressure injector pump blew apart.

The other news they gave me was it will not be a warranty repair as they say they found evidence that I've had a juice module installed. Even though it wasn't and hadn't been for awhile. They said they saw the gauges and the plug connections for the engine computer showed evidence of being "manipulated". They said that while all the computer codes show nothing if GM were to dig into it they would find evidence.

They gave me two options, either pay for the repair and keep the remainder of my engine warranty, or fight GM and probably still end up paying and having my warranty voided. Not much of a choice. Service manager said that GM is seeing a lot of these pump failures and are cracking down very hard on it.

There is no "evidence" of a stand alone Juice module. Gauges alone don't prove a thing. Tell them you checked that connection previously because your truck was missing at idle and you jiggled the connector. Don't let them play you like that.

Barnhart_Ram - Anything new on this??

I'd say find a new dealer

Thats BS

Tell them to prove to you that its on there and then prove it failed..

Until they can do it, they are playing you.

Might go in and have sit down with the high ups at the dealer. If your a loyal customer, dont forget to bring that up.. I bought xxx vehicles etc always helps.

Hey,
I find this thread fascinating because it just happened to me 2hrs ago. Mine is an '02 GMC Duramax with 66K on it. It's never been 'boosted' to my knowledge. I'll call the dealer in the am. Should prove to be interesting.

Sorry I haven't posted any updates. My sister in law passed away and dealing with the truck wasn't all that important...

Anyway, injector pump was replaced. Dealer first took exhaust manifold off, didn't find anything, then bore scoped it, didn't find anything, then started to disassemble the head when they finally figured out that it was the injector pump.

I don't know if that's good diagnostic procedure or not, sure doesn't seem like it.

Anyway, got my truck back. Ran great for about 3 days. Then started acting up. At about 60 going up a hill it would start to knock. Give it a little gas it would go away. Black smoke would sputter out the back. One time I took my foot off and the truck lurched and sent out white smoke. If I engaged the 5th gear lockout and drove it at about 2500rpm, would run like junk and send out a belch of white smoke every 30 seconds.

Hmmm, injector problem now or bad fuel? Searched this site and seem like it could be bad fuel. But, since I just had major work done on it, back to the dealer. Truck sat for a week before I could get it to the dealer.

Dealer couldn't replicate the problem. Since I never saw them take it off the lot, I bet they couldn't. Runs great a low speeds without any load on it.

Anyway, they plugged the computer thing into the truck and didn't see anything. They did pressure tests on the fuel filter and said it was partially clogged and should be replaced. Also said looked like I had water in my fuel. I said fine, replace the fuel filter (I didn't feel like messing with it right now). They did that and gave me back my truck. I asked "So what should I do about my contaminated fuel?" They didn't have an answer. Nice, tell me something's wrong but not how to fix it. Since the tank was full I added some Standadyne (sp?). Truck ran no better from the dealer to my house.

Today, truck is running good. Hopefully that's going to be the trend now. Can't wait until I get through this tank of gas and see if its cured for good.

If not, back to the dealer, but not this one. Can anybody recommend a good dealer in the St. Louis area?

Did they do the repairs under warrenty?

No.

And that's my fault. With everything else going on I didn't want to deal with it.

When you get everything straightened out down the road, write GM's local rep with how you were treated by this dealer and why you paid the bill.

i would raise bloody hell and demand that the old parts are returned to you as well.

If you paid for the repairs, your entitled to the return of the parts by law, and allowed to inspect those that must go back for warranty or have cores. You could also pay for the core if you had to until you get past this. Ask for reasons why its not covered and then have them prove there findings...

holy crap sound like bad diag. I have seen many pumps puke external and run out the back by the heads. Did the dealer take the head off? if so that is not your deal. ok lets be real most dealers cring at the dmax and find every reason to cry VOID. I would say the pump took a crap and yes maybe the filter need changed. Not hard to diag.
Man I am sorry. I JUST WISH SOME HIGH, HIGH, HIGH UP GM BOY WOULD SEE THIS. All the techs on this page must equal all the known good techs GM has. if you look at the number of tech to dealers. What we have 10 or so techs to what the 5-6 thousand dealers. GM is missing the boat.....Working where I am now we get Bosch info and training. Bosch is straight forward with training and issues. GM hides everything. Or waites until most of the known public and techs see the issues, see the fix. Than Gm admits failure. IE tech bullitens all come from tech solving issues.and the complaints come from the owners.
I am telling you we need to start a traviling tech crew across the USA to dispach all repairs to the techs on the board. To bad we could not convince GM it would save millions on combacks and dissatifised coustomers...
Patrick

Ok, this thread got my attention. I had my wife take mine in to the dealer this morning to have some steering column linkage doohicky replaced. Was making a "knocking" sound in the steering wheel. Apparantly this is common, they have been fixing them like mad. I also told them I noticed a diesel smell and wanted them to check it. Well, my wife just called and said they are keeping it overnight. Tech currently has the turbo off. She said if it was the injectors, they had some? I dunno? I had a Hypertech programmer installed but I returned it to stock before it went to the dealer. That cannot void my warranty, can it? I though I read somewhere that it could not? We are leaving at noon tomorrow for Boone with my 5th wheel!! I NEED MY TRUCK BACK!!!!!!

Oh yeah, I only have 24k miles on it, too!

good luck

Update: Dealer said I had a leaking injector pump (minor leak) and that it would not be ready until Monday. I had them put it back together so I can pull my camper this weekend to the mountains. They have one ordered, will have it installed Monday. I guess I can tolerate a little diesel smell for one weekend. I spoke to the GM tech back there who worked on it and he told me I should not have much of a problem using it.

Here's the latest from the dealer. It's not a hole in the header or anything like that. I wish they'd make up their minds. The high pressure injector pump blew apart.

The other news they gave me was it will not be a warranty repair as they say they found evidence that I've had a juice module installed. Even though it wasn't and hadn't been for awhile. They said they saw the gauges and the plug connections for the engine computer showed evidence of being "manipulated". They said that while all the computer codes show nothing if GM were to dig into it they would find evidence.

They gave me two options, either pay for the repair and keep the remainder of my engine warranty, or fight GM and probably still end up paying and having my warranty voided. Not much of a choice. Service manager said that GM is seeing a lot of these pump failures and are cracking down very hard on it.
I would ask the dealer what evidence they have.........because I would be having somebodies head on a platter for pulling that crap with me.........

I have a 4" exhaust, AFE Intake, Triple Pillar Pod, switches everywhere, lift pump...........etc........

The dealer only questioned me once and I told them why wouldn't I want to watch the EGT and Boost while towing........just because GM did not include the gauge why shouldn't I be able to install it if I want.............it monitors engine boost and egt and does not hurt nor change anything.......

Have one of the techs here run the VIN thru the GMVIS and see if they billed for warranty, if they did I would HANG THAT DEALERS HEAD ON MY WALL :mad:

Good Luck,

T:cool: NY

Man... I guess im lucky down here in Tyler. My Injectors went out about a month ago and i took my truck to the dealer. I left My Juice/Attitude on, i even was talking to the mechanic about it... nothing was said. They replaced all 8 under warenty.

thats GOOD

Can anybody recommend a good dealer in the St. Louis area?
I've taken mine to ELCO in Ballwin but just for piddly warranty stuff, no major work. The guy they always send me to seems to be a diesel guy but I don't know for sure.

Sorry about your sister-in-law.

Rip