Okay i have been searching this site for awhile but I'm having trouble putting everything together so i figured I'd post and see if i could get some help. Here are my current problems... light surging at idle (doesn't really bother me) and the best way to describe this next problem is a misfire. It does it most under a light load... climbing small grade on the highway around 1/3 to 1/2 throttle. The truck has 120,000 miles on it and has had the injectors replaced 3 times (i will post the vin history on it) I have done the ice pic fix on ALL injector plugs and checked main engine harness for loose/broken pins. I was a heavy machine operator and mechanic so i am not scared to get my hands dirty and i also have access to some Tech 2's from the rv place that i now work at. (also/was a Saturn dealer) I just haven't used it enough to really know what I'm doing. Any help would really be appreciated. Oh yeah and no mil light and i had a superchip tuner on it for about a year but i took it off for now.

Thanks,
Zach Matthews

Sorry about how long this is but it didn't copy and past right and I'm not that good with computers...

VIN : 1GCHK23224F212312
VEHICLE INFORMATION
Merchandising Model : CK25743 -2004 SILVERADO 2500HD 4WD CREW CAB Warranty Start Date : 04/06/2004
BARS Order Type : 70 - RETAIL - STOCK
Delivering Dealer : COLUMBIANA CHEVROLET HUMMER, INC.
100 PARKRIDGE DR
COLUMBIA , SC 29212-1732
(803) 732-6400
Selling Source : 13 - CHEVROLET
Site Code : 16754
Business Associate Code : 166151
Service Contract :

No

Branded Title :

No

Warranty Block :

No

PDI Status :

Paid
REQUIRED FIELD ACTIONS
Type

Number

Description

Posted Date

Status
RC
05037
SECOND ROW CENTER SAFETY BELT
N/A

Closed
SERVICE INFORMATIONAL ITEMS
Type

Number

Description

Posted Date

Status
SB

06047
DETERMINE IF ONSTAR CAN BE UPGRADED AT GM GLOBALCONNECT-SEE TSB 05-08-46-006
02/21/2007

See Bulletin
ON STAR AND XM SATELLITE RADIO INFORMATION
OnStar Equipped Yes OnStar Status Inactive Refer to Help page for details or:go to OnStar Online Enrollment (located on the "OnStar" tab in GM InfoNET) or (888)ONSTAR1 (888) 667-8271.
XM Equipped Yes XM Radio ID WXYB400E XM Status Inactive Refer to Help page for details or: www.xmradio.gm.ca or Dealer Hotline 1.877.GET.XMST (1-877-438-9677).
APPLICABLE WARRANTIES
Description

Effective Date

Effective Odometer

End Date

End Odometer
36/36000 BUMPER TO BUMPER LIMITED WARRANTY
04/06/2004
202 miles
04/06/2007
36202 miles
72/100000 SHEET METAL COVERAGE RUST THROUGH LIMITED WARRANTY
04/06/2004
202 miles
04/06/2010
100202 miles
60/100000 FEDERAL EMISSION
04/06/2004
202 miles
04/06/2009
100202 miles
60/100000 GM DIESEL ENG IN LD VEH WITH $100 DEDUCT AFTER BUMPER TO BUMPER LIMITED WARRANTY
04/06/2004
202 miles
04/06/2009
100202 miles
CLAIM HISTORY
R.O Date

R.O Number

Type

Labor Operation

Odometer Reading
11/20/2008

437609

#
F2383 - RING GEAR AND PINION - REAR DIFFERENTIAL - REPLACE 91766 miles
02/04/2008

430863

#
J5650 - FUEL INJECTOR REPLACEMENT 69785 miles
02/04/2008

430863

F
Z7200 - CORPORATE PARTS RETURN REIMBURSEMENT 69785 miles
02/04/2008

430863

#
Z5000 - DEALER/RETAILER TRADE(PART OBTAINED LOCALLY) 69785 miles
01/29/2008

430743

#
J5650 - FUEL INJECTOR REPLACEMENT 69677 miles
01/29/2008

430743

G
J5650 - FUEL INJECTOR REPLACEMENT 69677 miles
01/29/2008

430743

#
Z5000 - DEALER/RETAILER TRADE(PART OBTAINED LOCALLY) 69677 miles
01/29/2008

430743

F
Z7200 - CORPORATE PARTS RETURN REIMBURSEMENT 69677 miles
01/29/2008

430743

#
T2020 - TOWING 69677 miles
01/29/2008

430743

#
Z7902 - 2-DAY COURTESY TRANSPORTATION 69677 miles
09/04/2007

427113

#
R0754 - RADIO RECEIVER-RETURN TO AC/DELCO ESC 58058 miles
09/03/2007

427113

#
R0760 - RADIO, REMOVE AND REPLACE 58058 miles
08/23/2005

452438

#
E7700 - SHAFT, STEERING INTERMEDIATE - REPLACE 23059 miles
08/23/2005

452438

#
V1382 - 05037 - STITCH SEAT LOOP CLOSED 23059 miles
01/25/2005

400865

#
J6354 - POWERTRAIN CONTROL MODULE ENGINE REPROGRAMMING WITH SPS 13382 miles
01/25/2005

400865

#
J5650 - FUEL INJECTOR REPLACEMENT 13382 miles
01/25/2005

400865

#
Z7906 - 6+ DAY COURTESY TRANSPORTATION 13382 miles
03/08/2004

A12312

I
Z7000 - PRE-DELIVERY INSPECTION - BASE TIME 0 miles
CHECK HISTORY INFORMATION
Vehicle Has No Associated Check History Information.

VIN : 1GCHK23224F212312
CLAIM HISTORY
Repair Order Date : 11/20/2008 Repair Order Number : 437609 Odometer Reading : 91766 miles
Serviced By : COLUMBIANA CHEVROLET HUMMER, INC.
100 PARKRIDGE DR
COLUMBIA, SC 29212-1732
(803) 732-6400 Selling Source : 13 - CHEVROLET
Site Code : 16754
Business Associate Code : 166151
Cycle Date

Cycle Nbr

Case

Type

Labor Operation

Part

Auth Code

Person Code

Line Total

Comments
01/09/2009 968 01 # F2383 - RING GEAR AND PINION - REAR DIFFERENTIAL - REPLACE N/A A N/A $ 504.41 Y

Repair Order Date : 02/04/2008 Repair Order Number : 430863 Odometer Reading : 69785 miles
Serviced By : COLUMBIANA CHEVROLET HUMMER, INC.
100 PARKRIDGE DR
COLUMBIA, SC 29212-1732
(803) 732-6400 Selling Source : 13 - CHEVROLET
Site Code : 16754
Business Associate Code : 166151
Cycle Date

Cycle Nbr

Case

Type

Labor Operation

Part

Auth Code

Person Code

Line Total

Comments
03/25/2008 885 01 F Z7200 - CORPORATE PARTS RETURN REIMBURSEMENT N/A N/A N/A $ 523.00 Y
03/14/2008 882 01 # J5650 - FUEL INJECTOR REPLACEMENT 97303657 - INJECTOR B N/A $ 2011.12 N
02/22/2008 876 02 # Z5000 - DEALER/RETAILER TRADE(PART OBTAINED LOCALLY) 97303657 - INJECTOR N/A N/A $ 50.89 N

Repair Order Date : 01/29/2008 Repair Order Number : 430743 Odometer Reading : 69677 miles
Serviced By : COLUMBIANA CHEVROLET HUMMER, INC.
100 PARKRIDGE DR
COLUMBIA, SC 29212-1732
(803) 732-6400 Selling Source : 13 - CHEVROLET
Site Code : 16754
Business Associate Code : 166151
Cycle Date

Cycle Nbr

Case

Type

Labor Operation

Part

Auth Code

Person Code

Line Total

Comments
03/21/2008 884 01 G J5650 - FUEL INJECTOR REPLACEMENT N/A N/A N/A $ 284.27 Y
03/21/2008 884 02 F Z7200 - CORPORATE PARTS RETURN REIMBURSEMENT N/A N/A N/A $ 323.00 Y
03/07/2008 880 01 # J5650 - FUEL INJECTOR REPLACEMENT 97303657 - INJECTOR N/A N/A $ 1646.59 N
02/29/2008 878 02 # Z5000 - DEALER/RETAILER TRADE(PART OBTAINED LOCALLY) 97303657 - INJECTOR N/A N/A $ 73.76 N
02/29/2008 878 03 # T2020 - TOWING N/A N/A N/A $ 95.00 N
02/29/2008 878 04 # Z7902 - 2-DAY COURTESY TRANSPORTATION N/A ABG N/A $ 84.00 Y

Repair Order Date : 09/04/2007 Repair Order Number : 427113 Odometer Reading : 58058 miles
Serviced By : TECHNI-CAR INC.
450 COMMERCE BLVD
OLDSMAR, FL 34677-2808
Selling Source : 45 - A/C DELCO
Site Code : 18071
Business Associate Code : 192102
Cycle Date

Cycle Nbr

Case

Type

Labor Operation

Part

Auth Code

Person Code

Line Total

Comments
09/28/2007 834 01 # R0754 - RADIO RECEIVER-RETURN TO AC/DELCO ESC 12241695 A N/A $ 307.06 Y

Repair Order Date : 09/03/2007 Repair Order Number : 427113 Odometer Reading : 58058 miles
Serviced By : COLUMBIANA CHEVROLET HUMMER, INC.
100 PARKRIDGE DR
COLUMBIA, SC 29212-1732
(803) 732-6400 Selling Source : 13 - CHEVROLET
Site Code : 16754
Business Associate Code : 166151
Cycle Date

Cycle Nbr

Case

Type

Labor Operation

Part

Auth Code

Person Code

Line Total

Comments
09/18/2007 831 01 # R0760 - RADIO, REMOVE AND REPLACE N/A A N/A $ 94.39 N

Repair Order Date : 08/23/2005 Repair Order Number : 452438 Odometer Reading : 23059 miles
Serviced By : LOVE CHEVROLET COMPANY
PO BOX 8387
COLUMBIA, SC 29202-8387
(803) 794-9000 Selling Source : 13 - CHEVROLET
Site Code : 16467
Business Associate Code : 160592
Cycle Date

Cycle Nbr

Case

Type

Labor Operation

Part

Auth Code

Person Code

Line Total

Comments
08/26/2005 616 01 # E7700 - SHAFT, STEERING INTERMEDIATE - REPLACE 89060582 - SHAFT N/A N/A $ 98.34 N
08/26/2005 616 02 # V1382 - 05037 - STITCH SEAT LOOP CLOSED N/A N/A N/A $ 13.69 N

Repair Order Date : 01/25/2005 Repair Order Number : 400865 Odometer Reading : 13382 miles
Serviced By : COLUMBIANA CHEVROLET HUMMER, INC.
100 PARKRIDGE DR
COLUMBIA, SC 29212-1732
(803) 732-6400 Selling Source : 13 - CHEVROLET
Site Code : 16754
Business Associate Code : 166151
Cycle Date

Cycle Nbr

Case

Type

Labor Operation

Part

Auth Code

Person Code

Line Total

Comments
02/25/2005 564 01 # J5650 - FUEL INJECTOR REPLACEMENT 97303657 - INJECTOR BE N/A $ 722.83 N
02/25/2005 564 03 # Z7906 - 6+ DAY COURTESY TRANSPORTATION N/A W N/A $ 294.00 Y
02/18/2005 562 01 # J6354 - POWERTRAIN CONTROL MODULE ENGINE REPROGRAMMING WITH SPS N/A N/A N/A $ 48.36 N

Repair Order Date : 03/08/2004 Repair Order Number : A12312 Odometer Reading : 0 miles
Serviced By : J. AND M. CHEVROLET-OLDS, INC.
PO BOX 217
ZEBULON, NC 27597-0217
(919) 269-7478 Selling Source : 13 - CHEVROLET
Site Code : 16399
Business Associate Code : 114016
Cycle Date

Cycle Nbr

Case

Type

Labor Operation

Part

Auth Code

Person Code

Line Total

Comments
03/12/2004 464 01 I Z7000 - PRE-DELIVERY INSPECTION - BASE TIME N/A N/A N/A $ 106.48 N

CHECK HISTORY
Vehicle Has No Associated Check History.

I see a whole lot of injectors but I don't see a fuel pressure regulator in there anywhere. Nine times out ten, surging on these trucks is related to a bad fuel pressure regulator.

I hooked up the Tech 2 today and got some info...
Balancing Rates. Fuel Rail Pressure
#1= 4.3 Desired= 31
#2= 0.1 Actual= 29-33
#3= -3.8
#4= 0.3
#5= -0.3
#6= 1.0
#7= -2.2
#8= 1.1
Also some other things that didn't look right were ECT was 159 but was showing 180 on the gauge. The truck had been running in a 85 degree shop for 45 minutes and also the boost pressure sensor was reading 14psi (1.00volts) All info was taken in park at idle after truck had been running for 45 minutes. Thanks again for the help!

Zach Matthews

I see a whole lot of injectors but I don't see a fuel pressure regulator in there anywhere. Nine times out ten, surging on these trucks is related to a bad fuel pressure regulator.

yeah i guess its time for a fpr! Know anyone that sells them for a reasonable price?

I got my FPR from Oregon Fuel Injection for $230 delivered.

Also some other things that didn't look right were ECT was 159 but was showing 180 on the gauge. The truck had been running in a 85 degree shop for 45 minutes and also the boost pressure sensor was reading 14psi (1.00volts) All info was taken in park at idle after truck had been running for 45 minutes. Thanks again for the help!

If you believe your gauge on the cluster as being anything close to accurate, then I have some Arizona ocean front property I want you to look at. Its a guess and thats about all you can use it for. As for the 14psi on the boost sensor, thats a weird one. But I know if I hook up my predator even at idle in the driveway I get a boost pressure reading.

Boost sensor reads absolute pressure. At seal level Absolute pressure is about 14.7 psi. IIRC it has been debated on the forums before.

The gauge thing doesn't worry me. The 159 just didn't look right but oh well better cool then hot. Also i guess i need a fpr but do you think that's throwing the injectors off? If not then why is this truck eating injectors so bad. My tires last longer then the injectors. WTF?

Water in the fuel will cut the tips on the injectors. Trash in the fuel will also cause the injectors to stop up. Invest in a good aftermarket filter system.