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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 04-02-2016, 03:01 PM   #1 (permalink)
SickSpeedMonte
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New injectors, now has a miss

1993 K3500 auto, 135k miles. Original mechanical IP, to my knowledge.

The truck was having a rough time starting with a lot of smoke but it would clear up and run fine after 15 seconds or so. The injectors had probably never been changed with 135k miles on the truck, so I bought some rebuilt ones from Badger.

While tearing it down, I noticed a good bit of oil in the intake and on both ends of the turbo compressor. I put new bushings in the turbo, cleaned out the intake, and bought new injector lines from a Hummer off of Ebay because mine were pretty rusty. The new lines required me to remove a little fitting on the #1 injector line at the IP. The fitting just looks like an extension. There's no check valve or anything when you look inside it. I can't find any info online for it.

I got it all back together on Thursday night. I bled the driver side while my wife cranked it and then tightened the lines back up and it fired without much trouble. It has a bit of a lope though, sounding like it had a miss and it's smoking a lot too. I let it run for about 5 minutes to see if it needed to work some more air out, but it never got any better. If you rev it, it sounds like there's some kind of knock, but it sounded like that before when it had rough starts. I bled the other side while it was idling and no improvement there either.

I cracked each line while running, and the engine stumbles with each one cracked. This morning, I pulled the intake back off and double checked the firing order. Going back over everything, I did manage to pull one of the terminals apart on the temp sensor in the coolant crossover/thermostat housing. I pushed it back together, maybe that's open. Otherwise, I'm starting to run out of ideas.

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1993 Chevy K3500 CCLB Dually, 6.5TD, 4L80e, 4WD on Alcoa's with 265/70R19.5's. 4" Tough Country lift, forged lower arms
NAPA pre-filter, Raptor 100 GPH LP, OPS realy mod, Lube Specialists oil cooler kit, Glow Shift boost and supply fuel pressure gauges, 3" stainless DP, 4" stainless turbo back, 2.25" stainless crossover, all new hardlines underneith, and a 14 bolt full floater out of a Krispy Kreme delivery van

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Old 04-02-2016, 03:25 PM   #2 (permalink)
Freddyack
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Injector knock is normal after replacing them. Last time I did mine, I put a couple hundred miles on it before the knock finally went away.

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Old 04-02-2016, 03:27 PM   #3 (permalink)
SickSpeedMonte
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It's not just the knock though, it misses and smokes. If you rev it up, it runs really rough.

I cant find a replacement for this temp sensor anywhere either. All I can find is the one in the head for the gauge...
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1993 Chevy K3500 CCLB Dually, 6.5TD, 4L80e, 4WD on Alcoa's with 265/70R19.5's. 4" Tough Country lift, forged lower arms
NAPA pre-filter, Raptor 100 GPH LP, OPS realy mod, Lube Specialists oil cooler kit, Glow Shift boost and supply fuel pressure gauges, 3" stainless DP, 4" stainless turbo back, 2.25" stainless crossover, all new hardlines underneith, and a 14 bolt full floater out of a Krispy Kreme delivery van

Last edited by SickSpeedMonte; 04-02-2016 at 03:27 PM.
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Old 04-02-2016, 03:49 PM   #4 (permalink)
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Black smoke?
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Old 04-02-2016, 04:02 PM   #5 (permalink)
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Engine Coolant Temp Sensor, located on coolant crossover is AC Delco part # 213-928
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Old 04-02-2016, 05:05 PM   #6 (permalink)
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Start suspecting a tired IP, with the newer injectors the pump is working harder to push the fuel...
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Old 04-02-2016, 05:40 PM   #7 (permalink)
SickSpeedMonte
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Quote:
Originally Posted by Rattler1 View Post
Black smoke?
White. Looks just like it did on start up. It still starts rough as hell too. $400 into this project, 3 weekends, and all I've managed to do is break stuff and make it run worse.

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Originally Posted by sctrailrider View Post
Start suspecting a tired IP, with the newer injectors the pump is working harder to push the fuel...
I really hope not... It just never ends with this damn thing. Did I mention the passenger side GP's are stuck in there so hard that I broke the hex off of the body on the first one I tried? I have no idea what to do about that...

Is it common to only get 135k miles before having to replace the entire fuel system? The IP is the only thing fuel touches from the sender to the injectors that I haven't replaced at this point.
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1993 Chevy K3500 CCLB Dually, 6.5TD, 4L80e, 4WD on Alcoa's with 265/70R19.5's. 4" Tough Country lift, forged lower arms
NAPA pre-filter, Raptor 100 GPH LP, OPS realy mod, Lube Specialists oil cooler kit, Glow Shift boost and supply fuel pressure gauges, 3" stainless DP, 4" stainless turbo back, 2.25" stainless crossover, all new hardlines underneith, and a 14 bolt full floater out of a Krispy Kreme delivery van
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Old 04-02-2016, 05:43 PM   #8 (permalink)
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Quote:
Originally Posted by Freddyack View Post
Engine Coolant Temp Sensor, located on coolant crossover is AC Delco part # 213-928
Thanks Freddy. I bought one and had to replace the pigtail because my old one had two male terminals sticking out rather than the shrouded terminals for the weatherpack connector. It made no difference unfortunately.
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1993 Chevy K3500 CCLB Dually, 6.5TD, 4L80e, 4WD on Alcoa's with 265/70R19.5's. 4" Tough Country lift, forged lower arms
NAPA pre-filter, Raptor 100 GPH LP, OPS realy mod, Lube Specialists oil cooler kit, Glow Shift boost and supply fuel pressure gauges, 3" stainless DP, 4" stainless turbo back, 2.25" stainless crossover, all new hardlines underneith, and a 14 bolt full floater out of a Krispy Kreme delivery van
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Old 04-02-2016, 05:43 PM   #9 (permalink)
SickSpeedMonte
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Sorry for the rant guys. I'm just really frustrated.
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1993 Chevy K3500 CCLB Dually, 6.5TD, 4L80e, 4WD on Alcoa's with 265/70R19.5's. 4" Tough Country lift, forged lower arms
NAPA pre-filter, Raptor 100 GPH LP, OPS realy mod, Lube Specialists oil cooler kit, Glow Shift boost and supply fuel pressure gauges, 3" stainless DP, 4" stainless turbo back, 2.25" stainless crossover, all new hardlines underneith, and a 14 bolt full floater out of a Krispy Kreme delivery van
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Old 04-02-2016, 05:49 PM   #10 (permalink)
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Quote:
Originally Posted by SickSpeedMonte View Post
Thanks Freddy. I bought one and had to replace the pigtail because my old one had two male terminals sticking out rather than the shrouded terminals for the weatherpack connector. It made no difference unfortunately.

Something isn't right here. The sender with the two prongs is located on the coolant crossover on the passenger side. Its for the cold advance and high idle solenoid. The sender for the gauge that has the weatherpack connector is towards the front of the head on the drivers side.

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