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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 11-22-2017, 05:56 PM   #1 (permalink)
Qtbubbles
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What happens when tune up a 6.5

Hey guys wanted to get another post under my belt and share my 6.5 experience so far with everyone. So I bought my 98 ext cab 6.5 in January of this year , the truck was in relatively good shape owned by a 70 y/o man who bought it brand new in 1998 and meticulously took care of service intervals. The truck did have issues though, it was seriously down on power and threw black smoke when you would get on the throttle. I used the diesel place checklist to go through the truck when I looked at it , and found that the wastegate was freely moving at idle. (The sense of satisfaction was amazing lol ) So I knew the vacuum pump or WGS was bad, the truck was in good shape for age so I decided to take the gamble and picked it up at 2500 bucks. On the way home i stopped at oreillys grabbed a cheap WGS and plugged it in. To my amazement the truck instantly woke up , stopped smoking, and wastegate became functional. I was a happy camper. Shortly after purchase I got some advice from the guys on the forums oil selection in relation to climate and fuel additives that are a must on the 6.5 liter TD. I initially swapped the truck to 5w40 synthetic but eventually swapped back to 15w40 because I like the oill pressure while heat soaked and idling, as I simply do not put alot of miles on, but do get alot of runtime making shortish stops around town . For fuel I've used a combination of 8 oz Outboard 2 cycle with Powerservice Grey or white depending on season. Fast forward 5k miles and 10 mths later . Had the day off work so I decided to take my son to DQ for lunch and ice cream . We hit the road all is well , we pull up to a stop sign and the truck just shuts off , as if some ghostly spirit of the original owner reached over and turned the key off. We sat there for a couple minutes, the truck started back up ran fine to DQ, but as we pulled in it shut off again. We continued our lunch date and managed to get the truck back home , but it did kill twice more on the way home, once at 60 Mph. I was kinda shocked as the truck had run so well all year since the WGS replacement, but luckily I was ready for this . I knew this truck still had the stock standyne pmd in stock location , and I had a brand new unit with relocation kit and #9 resistor under the backseat. As soon as I got home I popped the hood, and installed my new PMD with heatsink near the drivers fenderwell. Now one thing I had ignored since the day I bought this truck was a small tick, nothing loud just annoying in the morning. I chalked it up to a noisy lifter/injector pinging. After spending some time under the hood installing my PMD and heatsink I noticed how badly the exhaust manifold bolts had deteriorated. This was concerning because I have owned many a hotrod and ****box, and had more than one project become hampered by rusty nasty exhaust manifold bolts breaking or even pulling threads out an aluminum head . I also noticed the injectors and glowplugs were in about the same shape. So I thought to myself you know what I really like this truck lets put some cash on it. Went out and got some new ac delcos, bosch injectors, tygon custom return lines, new lift pump. ( even though mine was fine it was terribly rusty) Here is where this whole story gets fun, I pulled the truck apart (no broken ex mani bolts, glow plugs or injectors )and found that the tick wasn't a lifter at all, but in fact, was the #6 ex mani port bleeding as a result of mating surface decay. Now the injectors I wish I had taken a picture of they were THRASHED, I mean absolute garbage, i cannot believe that truck ran the way it did with those injectors, almost certainly stock. The glowplugs were bad but not gone ,came out in one piece. I took 2 thousands off the exhaust manifolds used a generic ex gasket from oreillys , which I had to cut in a few places to clear oil dump and oil dipstick . I also used all new stainless bolts and washers for everything which I sourced from fastenal, and a turbo gasket from weavers. I got the welder out , deleted the trap and muffler and fixed up a straight pipe setup. Now I was happy with the power levels after i had fixed the WGS, and everyone knows 6.5's are not powerhouses, but after doing all the work, I'm telling you guys I CANNOT believe the difference . The tick is now completely gone , you can feel the turbo is spooling faster and easier, and a huggggggggggge acceleration increase is heavily apparent.This is how this truck was supposed to run. I wanted to thank the DieselPlace forum because everything I did , I basically copy pasted from previous forum users troubleshooting. So thanks guys . My next project is going to be a boost guage, oil cooler lines, smal intercooler, and egt. That will most likely be the extent of my mods to this truck as I really want to make her last. Let me know if anyone would like to see pics of the work i did or the upcoming mods. Thanks again guys and have a friggin good one.

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1996 Ext. Cab Dually
6.5 145k PMD Relocation Kit #9 Res.
Full 3 inch Exhaust Trap and muffler delete
Custom Air Intake (Back to stock mpg suffered)
Intercooler soon to come
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Old 11-22-2017, 06:20 PM   #2 (permalink)
vstech
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Pics are always welcome on here!

Look into the feed the beast mod...

Worth it.

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6.5block in 6.2 trim with a TH400 attached
95 6.5 block, most of the IP, flywheel, and pressure plate.
95 Chevy Suburban 1500 "blue bomber"
2000 Chevrolet extended cab long bed 2500 6.5L HO
94 GMC extended cab long bed 6 lug truck 6.5L
Z71 ext cab standard bed S vin with a blown headgasket.
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Old 11-22-2017, 06:21 PM   #3 (permalink)
OkDually
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Nice work

Be sure to change out the Harmonic Balancer and Pulley as well. They are just as important as those oil cooler lines!
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1996 K3500 6.5L,( "F" Eng #141 cast block) 5 speed manual, crewcab, dually longbed: 208,000mi.
Diamond Eye 4" Turbo Back Exhaust w/2.5" Flo-Pro Crossover
AirDog II DF165 w/ tank sock delete - XDP
TD-Max boost controller - Kennedy Diesel
OPS extension hose - Leroy Diesel
Glow Plug Harness- PT Wiring Solutions
Glowshift Maxtow EGT,Boost, Fuel gauges
Boost & Fuel Pressure Bolts - Leroy Diesel
2/0 Battery Cable Upgrade - PT Wiring Solutions
PMD w/#9 resistor and Re-Location Kit, mounted to bumper - Leroy Diesel
GM-5 Turbocharger
4.10 gear ratio
OptiLube summer + Formula


Proud member #1039 of The 3500 Dually Club

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Old 11-22-2017, 08:28 PM   #4 (permalink)
Qtbubbles
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The harmonic balancer and pulley are on the list too, I check it everday XD. My rubber is in great shape so I think it will come last. Gonna go check out the beast mod.
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1996 Ext. Cab Dually
6.5 145k PMD Relocation Kit #9 Res.
Full 3 inch Exhaust Trap and muffler delete
Custom Air Intake (Back to stock mpg suffered)
Intercooler soon to come
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Old 11-28-2017, 10:14 AM   #5 (permalink)
Firstoneman
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Difficulty

Quote:
Originally Posted by Qtbubbles View Post
I got the welder out , deleted the trap and muffler and fixed up a straight pipe setup.
Can you take a pic of the new plumbing and show it. I'd like to see how it looks and what you did. What is the difficulty level of this mod? Is it something some guys at my Tuffy can do or should I see about my friend doing it who is an airplane mechanic and welder.

Cheers!
Dave
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Old 11-28-2017, 10:34 AM   #6 (permalink)
Firstoneman
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Source for these

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Originally Posted by OkDually View Post
Nice work

Be sure to change out the Harmonic Balancer and Pulley as well. They are just as important as those oil cooler lines!
Any opinions on best sources for Harmonic Balancer and Pulley?
Thanks.
D
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A diesel novitiate.

'94 Suburban 6.5L Turbo C2500, AT, 212K miles(current 2018), no radio.
Previously a Bio-diesel conversion, reverted by 2nd owner (I am 3rd). Came with: Facet Posi-Flo Lift Pump, K&N Air Filter, Detroit Diesel 8.2L filter base w/Napa 3122.
My mods: Accurate Diesel PMD w/6' Harness (2016 moved to bumper). Detroit Diesel Fuel Filtration: Baldwin FB1301 base, BF781 Filter as primary (2016), Fluidampr (2018), Lubrication Specialists Oil Lines & Cooler (2018).

'91 Chevy ˝ ton, 5.7L 350 V8 gasser 4x4, ext cab & short bed. No mods…just some replacement parts & nice tires
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Old 11-28-2017, 10:48 AM   #7 (permalink)
OkDually
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Quote:
Originally Posted by Firstoneman View Post
Any opinions on best sources for Harmonic Balancer and Pulley?
Thanks.
D
You can browse online for prices or shop locally for them.

Rock Auto is a good source and will give you a 5% discount if you use their code on the Sponsor page here:
https://www.dieselplace.com/forum/68-...ount-code.html


Harmonic Balancer:
OEM: 10154688
Fluidampr: 800141 ( Fix-all but expensive)
Powerbond: O'Reilly's Part # PB1490N

Pulley:
Dorman: 594-037
Powerbond (@ O'reilly's): PB1194N

Leroy Diesel also has a Billet Pulley that is a fix- all solution.
__________________
1996 K3500 6.5L,( "F" Eng #141 cast block) 5 speed manual, crewcab, dually longbed: 208,000mi.
Diamond Eye 4" Turbo Back Exhaust w/2.5" Flo-Pro Crossover
AirDog II DF165 w/ tank sock delete - XDP
TD-Max boost controller - Kennedy Diesel
OPS extension hose - Leroy Diesel
Glow Plug Harness- PT Wiring Solutions
Glowshift Maxtow EGT,Boost, Fuel gauges
Boost & Fuel Pressure Bolts - Leroy Diesel
2/0 Battery Cable Upgrade - PT Wiring Solutions
PMD w/#9 resistor and Re-Location Kit, mounted to bumper - Leroy Diesel
GM-5 Turbocharger
4.10 gear ratio
OptiLube summer + Formula


Proud member #1039 of The 3500 Dually Club

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Old 11-28-2017, 01:17 PM   #8 (permalink)
deejaaa
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it's recommended to put the PMD on the bumper and out of the engine bay. heat soak occurs when the engine is off also.
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"Member #1 of The A$$h0le Club" Your signature is most appropriate.
Black 93 1 ton crew cab, fuel/boost gauge, spin-on pre-FFM filter, 6.5 stock, 30 gal bed mounted tank,soon to be siphon tank, w/Goldenrod on feed, brought home 9/4/08, Turbo that starts with A, OEM crossover, quad headlights, reskinned door cards/headliner, 2 power-ports on lower dash, hour-meter, 235/85R16LT tires, GV unit(2K rpm at 68 mph w/4:10's), TCI EZ-TCU 4L80, working on DD Radio install, OEM tank removed but soon replaced.
Proud Member #11 of the 3500 CC LB SRW Club
Member #1 of The A$$h0le Club
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...get it under control or someone might cave in your head someday.....People get killed everyday because of attitudes like yours. All it takes is running into the wrong person at the wrong time. You shoot off your mouth and they shoot off your head and suddenly you're pushing up daisies.
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