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6.5L Diesel Engine Discuss the 6.5 GM diesel engine & associated components. Automatic transmission questions & problems belong in the 4L80/85 - 4L60E - 6L90 Transmission Forum

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Old 11-24-2015, 05:36 PM   #1 (permalink)
saffron98
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6.5 Wont Start / Turn Over

https://drive.google.com/open?id=0B7...EJvTHlmVGtwMGc

This was my start after our first freezing overnight temps. Truck has always had long starts. Injector pump finally fail? PMD?

Replaced the battery (2 new batteries now) and get this:

https://drive.google.com/open?id=0B7...UdhdXFkOFRqZGs

Recent engine maintenance from the last few weeks:

  1. Bosch Duraterm Glow Plugs
  2. Badger Diesel Turbo replacement
  3. Heath turbo master
  4. Starter
  5. Serpentine Belt
  6. Running Diesel Kleen
  7. Oil Filter / Air Filter / Fuel Filter
  8. 2 New Batteries
  9. Fresh coolant / Heater hoses.
Truck was running great / boosting fine until I tried to start it this morning. Luckily I filmed the 1st crank because their was frost windshield and I thought it would be an interesting start. I've never owned this truck through a winter.

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1997 GMC 3500 Dump 6.5L 2WD
Badger Diesel rebuilt GM8 Turbo
Glowshift Boost Gauge
Heath Diesel Turbo-Master
4" Turbo Back Diamond Eye Exhaust / 2.25" Cross Over Pipe
SS Diesel HD Lift Pump
Bosch Injectors / Duraterm Glow-plugs
Heath Diesel PMD Isolator System
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Old 11-24-2015, 06:08 PM   #2 (permalink)
grabowski
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The highest recommendations are in Bold below
________
1985 GMC 6.2 manual 4x4 3/4+ton 64,013 miles (5-1-19)
______________
The Blowby Queen '94 Chevy 'burb Silverado K2500 4L80E 4.10. Quadstar Tuning.
Midland Diesel Las Vegas Diesel rebuilt 5221 Blue Label IP with ULSD Upgrade & rebuilt Bosch injectors @ 2200psi. 235-85 on 16" PYO alloys. Bilstein HDs, Hellwig rear sway bar. Heath TM. Fluidampr. S&B oiled filter Intake, Provent 200 W/catchcan. Bosch Duraterm GP W/PT Solutions GP harness. WJ FTB. AC Delco Tstat & Red Line Water Wetter. hxtasy PMD #2 resistor on Heath Isolator 4. LS 1/2" oil cooler & lines. OPS Relay Mod & Leroys Hose. Diamond Eye exhaust. Heath 2.5" crossover. W/T Grille. VDO EGT & Vac/Boost gauge with copper line & Leroys Boost Bolt.


- 12-13-16 Out Of Commission @ 194,680k, 50 miles after Teds Mil Takeout Install. Bad noises in the motor.
- 12-29-16 #7 lifters and pushrods replaced and still sounds like a metal trash can half full of hammers rolling down a scree field.
- 03-01-17 @ 194,802 miles she's no longer mine.

12-28-2016: I no longer recommend Badger/kr_services and Ted's Trucks
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Old 11-24-2015, 06:08 PM   #3 (permalink)
JMJNet
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Let me say it again "NEVER ASSUME THAT NEW PARTS ARE GOOD".

Load test those 2 new batteries one at a time.
I have heard member with new batteries only last a few days.

Also check the fuses and all the cables and grounds and terminals.
Those thing do not have to be good when temp is high but any bad connections may cause issue in the winter when it needs all the amps.
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1995 GMC Suburban:
PMD in Bumper
Leroy Diesel Flight System PMD
Leroy Diesel Oil Cooler Line
4" Warpspeed Exhaust
Kennedy Diesel LP/OPS Harness
Bosch Duraterm GP
Heath Turbo-Master
AD244 Alternator

Last edited by JMJNet; 11-24-2015 at 06:10 PM.
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Old 11-24-2015, 06:50 PM   #4 (permalink)
Tr00b
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Quote:
Originally Posted by JMJNet View Post
Also check the fuses and all the cables and grounds and terminals.
x2 including the starter itself.
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1996 GMC K1500xcab 6.5 3.73 4L80E rear bags Bought at 99k 12/13 now 138k 9/17
Repairs:
BWD OPS 1/14 Heath PMD kit 3/14 Airtex boost solenoid 6/14 Lube Specialist cooler lines and cooler, rad support mounts, Pro Comp ES9000 Shocks, rear brakes 7/14 Interstate Batts, Cooper AT3 tires, Hummer H3 rims, stepper motor 4x4, coolant flush 11/14 Stabilizer bar links, soot trap gasket 9/15 Dorman tank, sending unit/sock delete, filler neck, filler neck, hose, Leroy's Tank Barbs, SAE30R9 lines, WIX filter head and prefilter with brackets by paleyjim, intake manifold gaskets 3/16 Used transmission, dipstick tube, fluid flush, drain plug pan by paleyjim, power steering fluid flush, transfer case seals and fluid 9/16 Duraterms 11/16 Ball Joints and wheel bearing drivers side. Powerstop pads, lubed sliders 4/17 AD244, Leroy's Flight Systems PMD 9/17
Performance:
Ashland Muffler 2.5 X-over 12/13 FTB FFM by paleyjim, ported upper egr delete S-code, lower F-code, ported IP fitting, FASS DRP-02 lift pump 3/16 Transgo Shift Kit by paleyjim, Energy Susp. engine+trans mounts 9/16 Ported GM8, Diamond Eye, Quadstar tune 11/16 K47 Box, Glowshift 3-1 1/17 Leroy's Billet Crank pulley, Fluidampr. 9/17
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Old 11-24-2015, 06:52 PM   #5 (permalink)
Freddyack
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Watched your first video, did not have permission to watch the second.

The starter did not sound healthy to me. But my ears like the rest of me are getting old.

Hit the starter as soon as the Wait To Start light goes out. Dont wait for the flashing Wait To Start.
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Last edited by Freddyack; 11-24-2015 at 06:53 PM.
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Old 11-24-2015, 08:38 PM   #6 (permalink)
saffron98
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Quote:
Originally Posted by Freddyack View Post
Watched your first video, did not have permission to watch the second.

The starter did not sound healthy to me. But my ears like the rest of me are getting old.

Hit the starter as soon as the Wait To Start light goes out. Dont wait for the flashing Wait To Start.
New link should work:

https://drive.google.com/file/d/0B7q...ew?usp=sharing

I'm suspecting the "new" starter is shot -I've had it on there for a few months and less than a couple hundred miles.

I tried tapping it with a hammer while cranking the engine but no luck. The starter spins but it sound like the solenoid does not engage.
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1997 GMC 3500 Dump 6.5L 2WD
Badger Diesel rebuilt GM8 Turbo
Glowshift Boost Gauge
Heath Diesel Turbo-Master
4" Turbo Back Diamond Eye Exhaust / 2.25" Cross Over Pipe
SS Diesel HD Lift Pump
Bosch Injectors / Duraterm Glow-plugs
Heath Diesel PMD Isolator System
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Old 11-25-2015, 09:00 AM   #7 (permalink)
Freddyack
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Yeah, I think you are right. The starter does not sound like it is engaging the flex plate/fly wheel.

Make sure the starter has the front support bracket installed: https://www.dieselplace.com/forum/63-...ml#post7277730. Part #9 in the diagram.

Also, you need to wait 60 seconds after you attempt a start for the starter to cool down. Also, so the PCM resets and glow plugs will run a full heat cycle. Wait to Start light should be on for 8-10 seconds, and the light should stay on longer the colder it gets.
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Last edited by Freddyack; 11-25-2015 at 09:05 AM.
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Old 11-25-2015, 03:39 PM   #8 (permalink)
saffron98
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Quote:
Originally Posted by Freddyack View Post
Yeah, I think you are right. The starter does not sound like it is engaging the flex plate/fly wheel.

Make sure the starter has the front support bracket installed: https://www.dieselplace.com/forum/63-...ml#post7277730. Part #9 in the diagram.

Also, you need to wait 60 seconds after you attempt a start for the starter to cool down. Also, so the PCM resets and glow plugs will run a full heat cycle. Wait to Start light should be on for 8-10 seconds, and the light should stay on longer the colder it gets.
Shop confirmed the starter is bad AND the flywheel is shot -that is why it failed prematurely. Starter will get replaced under warranty but the flywheel labor is going to be around $400
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1997 GMC 3500 Dump 6.5L 2WD
Badger Diesel rebuilt GM8 Turbo
Glowshift Boost Gauge
Heath Diesel Turbo-Master
4" Turbo Back Diamond Eye Exhaust / 2.25" Cross Over Pipe
SS Diesel HD Lift Pump
Bosch Injectors / Duraterm Glow-plugs
Heath Diesel PMD Isolator System
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Old 11-25-2015, 04:25 PM   #9 (permalink)
JMJNet
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That is usually caused by whoever install the starter last time did not install the starter's back bracket (towards the front of truck so it is called front support) properly.
So, after you fix it, make sure that back bracket is installed properly/tightly.

It has caused a lot of people with issue like this.
__________________
1995 GMC Suburban:
PMD in Bumper
Leroy Diesel Flight System PMD
Leroy Diesel Oil Cooler Line
4" Warpspeed Exhaust
Kennedy Diesel LP/OPS Harness
Bosch Duraterm GP
Heath Turbo-Master
AD244 Alternator

Last edited by JMJNet; 11-25-2015 at 04:26 PM.
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Old 12-04-2015, 01:25 PM   #10 (permalink)
saffron98
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Quote:
Originally Posted by JMJNet View Post
That is usually caused by whoever install the starter last time did not install the starter's back bracket (towards the front of truck so it is called front support) properly.
So, after you fix it, make sure that back bracket is installed properly/tightly.

It has caused a lot of people with issue like this.
New flex plate was installed and the starter was replaced under warranty. I verified that the front bracket on the starter was installed.

Old flex plate was well worn after +200K Replaced it with an ATP Z136

20151204_122605_resized.jpg

20151204_122611_resized.jpg

20151204_122645_resized.jpg

20151204_122703_resized.jpg

Even with the new flex plate, I am still having a hard start issue. After sitting for 5 hours in 45 degree weather:

https://drive.google.com/file/d/0B7q...ew?usp=sharing

Codes: P0370 / P0251

Bad IP causing hard start?

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1997 GMC 3500 Dump 6.5L 2WD
Badger Diesel rebuilt GM8 Turbo
Glowshift Boost Gauge
Heath Diesel Turbo-Master
4" Turbo Back Diamond Eye Exhaust / 2.25" Cross Over Pipe
SS Diesel HD Lift Pump
Bosch Injectors / Duraterm Glow-plugs
Heath Diesel PMD Isolator System
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