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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 07-11-2019, 07:22 PM   #1 (permalink)
FuzzyRev
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I have a 1994 6.5l Extended Cab Pickup truck that originally had a large (and heavy) deluxe camper mounted on it. I used the truck and camper to pick up and deliver rescue dogs all over the south and Midwest.
We removed the heavy camper and replaced it with an ancient (like me) Palomino pop-up camper to conserve weight as the truck has been having severe power issues on anything resembling an incline. That helped until the day I got some dirty fuel which required replacing the air filter, fuel filter, and the fuel pump. Afterwards, there was temporarily awesome power like when we first bought the truck used 15 years ago from the original owner. Unfortunately, the fix didn't last...
Now the engine runs rough again and sometimes does not want to start again when warm. I have a "Service Engine Soon" light that comes on with highway travel. The truck is running rough but still has enough power for hills at 50mph rather than the 35mph of the past.
I live in rural Kansas, I'm retired, and I'm deaf. I need my truck to be reliable. Can anyone suggest anyone who can afford ably help?

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Old 07-11-2019, 07:51 PM   #2 (permalink)
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Welcome to DieselPlace
I moved your post over to the 6.5L section of the forum for better views and responses to your issues and questions.

I would start by checking for any codes the ECM may have recorded.
You can check for codes using a paperclip and follow the info in this link:

https://dieselplace.com/forum/showthread.php?t=16399

If you do have any please post them here.

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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 07-14-2019, 10:03 AM   #3 (permalink)
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FuzzeyRev also make sure your lift pump is working.I noticed that you replaced it but if the oil pressure switch has burned out,the lift pump won’t work at least on the 94 model year.Try loosening the brass T fitting next to the thermostat.With the engine idling,loosening the T fitting and if the engine stalls the lift pump isn’t pushing fuel to the filter bowl because of a burned out oil pressure switch.If that’s the case only buy a new acdelco switch.If fuel spews from the T valve,the lift pump is operating.
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1996 GMC Sierra ext.cab Z71....with new genuine GM 6.2 660 short block,4L80E/6.5TD cylinder heads,DS4 5521S,82' 6.2 rocker arms,acdelco TP1069/Racor 20S fuel filters,4" diamond eye exhaust,3.73 G80 locker,stanadyne 37818 injectors

1996 Chevy K1500 Z71.....with '99 6.5 506 goodwrench van engine,88-93 6.2 diesel Napa y-pipe,'87 700R4,acdelco TP630F/Racor 20S fuel filters,Bosch non-turbo injectors,stanadyne blue tag 5088

1993 Chevy K1500 Z71...with 97' 6.5 TD 506 block,82' 6.2 rocker arms,stanadyne 37818 injectors,stanadyne blue tag 4911,DSG girdle,reman 700R4,Banks boost/pyrometer gauges,acdelco TP1069/TP943 fuel filter system,4 diamond eye exhaust/2 piece crossover

2008 Mercedes Benz E320 3.0 V6 turbo diesel

2013 Volkswagen Passat 2.0 TDI
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Old 07-14-2019, 02:20 PM   #4 (permalink)
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There are two additional filters to consider.

Inside the fuel tank is a plastic sock filter that should only be replaced with an ACDELCO DIESEL sock.
Also, inside the fuel filter bowl, there is a plastic screen that clogged up.
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94 GMC extended cab long bed 6 lug truck 6.5L
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Old 07-16-2019, 05:07 PM   #5 (permalink)
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Lift pump is good, error code that we finally got was 78 which apparently is the solenoid waste trap? Where in the world do I even start looking for this?
And before I forget to say so, THANK YOU, all of you, for your help here. I am learning a whole lot even when I sound totally ignorant. My gasoline mechanic is learning too, and delighted to be so doing. He is more than willing to help install the parts I need when we can get them.
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Old 07-16-2019, 05:09 PM   #6 (permalink)
FuzzyRev
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ECM logged Error Code 78 only (Solenoid Waste Trap or something that sounds similar to that?). Engine is running better, but starting issues continue obviously due to the solenoid problem.
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Old 07-16-2019, 05:16 PM   #7 (permalink)
Sirleitet
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Code 78 is the turbo wastegate solenoid. Try liberally lubricating it with some WD-40 and tap it lightly a couple of times to see if the problem dissapears.
If it doesn't, replace it with a AC-delco oem part only. If you go aftermarket on these trucks, you're only inviting more problems in the near future.

Edit: The starting issues is probably some other problem like glow plugs or injectors etc etc.
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1995 Chevrolet Cheyenne K2500 6.5TD / Suzuki Katana GS650G
Mods: Racor 690r fuel filter/w heater, new front face, new radiator and support bushings. Repaired both cab corners & frame. (Rust.)
Relocated PMD, DIY extended wiring harness. # of PMD replaced since owned truck in 2013: 5.

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Old 07-16-2019, 05:25 PM   #8 (permalink)
FuzzyRev
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We replaced the fuel pump with AC Delco fuel pump/
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Old 07-16-2019, 05:26 PM   #9 (permalink)
FuzzyRev
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Thank you. Is it safe to lubricate the solenoid wastegate with WD40?
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Old 07-16-2019, 05:44 PM   #10 (permalink)
OkDually
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Quote:
Originally Posted by FuzzyRev View Post
Lift pump is good, error code that we finally got was 78 which apparently is the solenoid waste trap? Where in the world do I even start looking for this?
And before I forget to say so, THANK YOU, all of you, for your help here. I am learning a whole lot even when I sound totally ignorant. My gasoline mechanic is learning too, and delighted to be so doing. He is more than willing to help install the parts I need when we can get them.
The wastegate solenoid is a common issue with the 6.5L

You can spray some WD 40 into the vacuum port and give the solenoid some light taps to free the internals but if they are worn you will need to replace.
Order ACDELCO Part # 2141073 (Wastegate solenoid)
Our supporting vendor Rock Auto will probably be the cheapest online source.
If you do use them, don't forget to use the 5% discount code found on their vendor page:
https://www.dieselplace.com/forum/68...15-2019-a.html

When it comes to any part that is electrical in nature for the 6.5L , use only AC/Delco replacement parts.
Using aftermarket electrical parts bring unwanted gremlins.

__________________
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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