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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 01-10-2019, 04:07 PM   #1 (permalink)
97Blue3500
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Ol’ Blue is sick

Howdy. Mine is a 1997 K3500 6.5 farm truck with 133K miles. I have had it a year and an old problem has resurfaced. When I bought it, I ran it on the highway and if I let off the acceleration at speed, it would start “popping” and kicking out black smoke out of the exhaust. The guy found the vacuum pump wasn’t working and when he replaced it with a working used one, the problem went away. Fast forward to last summer and it started doing it again. Naturally I assumed the vac pump died, but it pulls 20 in Hg all the way to the waste gate. The waste gate lever moves up and down as I apply and remove vacuum. The problem is inconsistent. Sometimes I can drive the truck 20 miles and get up to 90 mph without it missing a lick and other times it will immediately start doing it after stepping on the accelerator after just idling for 1/2 hour in park. If it does it during the idling, it immediately settles out when put in gear, but start again if I shift to park or neutral and accelerate. I have had it do it when slowly going down a steep hill with my tractor and trailer, or after settling out to speed after climbing a hill with a load. It never does it under acceleration, always after I let off the pedal. I will coast it along and all of a sudden it feels like it shifts and then immediately settles smooth, but does not seem to be tied to the transmission because of the idling in park occurrences. The turbo appears to be working as my boost pressure varies from 3-9 psi depending on acceleration/speed/load.
Any ideas?

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Old 01-10-2019, 04:28 PM   #2 (permalink)
OkDually
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Welcome to DieselPlace
I moved your post over to 6.5L section for better views and responses to your issue.


Have you gone through all of your grounds?
https://www.dieselplace.com/forum/sh...d.php?t=163087

Checked for any DTC codes?

Remove your fuel cap. Do you hear a large "Whoosh" sound?
If so, then you have a fuel restriction and need to modify your fuel cap for better venting.
https://www.dieselplace.com/forum/63...ml#post6387506

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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 01-10-2019, 05:52 PM   #3 (permalink)
97Blue3500
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I am currently working on the passenger side glow plugs (I also have a cold weather starting issue). I have not done a code check. Can Autozone do that like on other cars? I never thought about the fuel cap. I did get a fuel pressure gauge and tubing, but haven’t hooked it in yet.
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Old 01-10-2019, 06:40 PM   #4 (permalink)
OkDually
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Quote:
Originally Posted by 97Blue3500 View Post
I am currently working on the passenger side glow plugs (I also have a cold weather starting issue). I have not done a code check. Can Autozone do that like on other cars? I never thought about the fuel cap. I did get a fuel pressure gauge and tubing, but havenít hooked it in yet.
Any of your local auto parts stores should be able to read the codes for you.
If any are present be sure to post them here.

Also, if you haven't done so already, change your fuel and air filters.
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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 01-10-2019, 07:30 PM   #5 (permalink)
97Blue3500
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He put in a K & N and I’ve put only a few hundred miles on it. I haven’t done the fuel filter.
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Old 01-10-2019, 07:40 PM   #6 (permalink)
OkDually
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Quote:
Originally Posted by 97Blue3500 View Post
He put in a K & N and Iíve put only a few hundred miles on it. I havenít done the fuel filter.
Just a heads up.
A K & N filter in a diesel engine and it being a farm truck are two combos that
can cause issues.

Over time.. no matter how much or well you clean that cotton filter material it will hold dirt and become very restrictive.
Diesel engines use way more air than a conventional gasoline engine.

Using a stock paper filter will serve your 6.5L way better.
__________________
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 01-12-2019, 08:14 AM   #7 (permalink)
97Blue3500
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OK, I just ordered an AC Delco A1301C air filter. My truck is a VIN “F”—Heavy Duty.
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Old 01-12-2019, 12:08 PM   #8 (permalink)
56pan
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Quote:
Originally Posted by OkDually View Post
Just a heads up.
A K & N filter in a diesel engine and it being a farm truck are two combos that
can cause issues.

Over time.. no matter how much or well you clean that cotton filter material it will hold dirt and become very restrictive.
Diesel engines use way more air than a conventional gasoline engine.

Using a stock paper filter will serve your 6.5L way better.
X2 on the K&N filter.
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'93 C2500 280,000 m.
60k on new AMG mil. surplus engine
Turbo with name that starts with A.
Straight pipe exh. (but it ain't that loud).
Peninsular intercooler
Boost, EGT, Glowshift intercooler in/out temp. 3 guage pod.
Rebuilt complete susp. with polyurethane bushings. (Bad idea).
20k on GM 4L80E rebuilt trans.
Dual thermostat/Duramax fan/high flow water pump.
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Old 01-12-2019, 07:48 PM   #9 (permalink)
97Blue3500
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As for the fuel filter, it’s just the one at the fuel filter manager behind the intake manifold, right?
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Old 01-12-2019, 08:21 PM   #10 (permalink)
OkDually
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Quote:
Originally Posted by 97Blue3500 View Post
As for the fuel filter, it’s just the one at the fuel filter manager behind the intake manifold, right?
Yes
There is also a secondary screen filter down inside of the bottom of the Manager.
Be sure to inspect it as well

__________________
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


Last edited by OkDually; 01-12-2019 at 08:22 PM.
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