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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 08-30-2019, 01:44 PM   #1 (permalink)
Mdifed
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6.5 Diesel Rough idle, Stalling, etc..

Hi everyone I am new to this page and I’m seeking help. I have a 2000, Chevy K3500 Rack Body with a 6.5 Diesel (134,000) miles on it.
The problem all began with water in the fuel. We changed the tank, flushed out the diesel, and put a new injector pump right off the bat. After all that work the truck still kept stalling because not enough fuel was reaching to the fuel housing. The sock on the sending unit kept getting clogged and the truck would stall. We removed the sock and some how there was still debris on the bottom of the new tank. We ended up returning the new injector pump since it got dirty and put a new one in, as well as brand new injectors. The PMD has been relocated to the front of the truck under the bumper 5 years ago. The truck starts, when it gets warm it begins to idle and the engine shakes, and when I take it for a spin and slam on the pedal the truck would just shut up. If anyone can help me that would be great, thanks for your time.

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Old 08-30-2019, 02:21 PM   #2 (permalink)
OkDually
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Welcome to DieselPlace
I moved your post over to the 6.5L section for better views and answers to your issue.



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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
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OPS extension hose - Leroy Diesel
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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
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Old 08-30-2019, 03:41 PM   #3 (permalink)
JMJNet
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Air in fuel so when you fix it, there are still some leak or the debris still clogging.
Nothing you can do except putting a filter somewhere.
Did you replace the Lift Pump also?
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Old 08-30-2019, 07:47 PM   #4 (permalink)
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Yes I replaced the lift pump as well, should I get new lines? I don't understand why it stalls either. Maybe the PCM is bad again.
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Old 08-30-2019, 07:50 PM   #5 (permalink)
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Quote:
Originally Posted by Mdifed View Post
Yes I replaced the lift pump as well, should I get new lines? I don't understand why it stalls either. Maybe the PCM is bad again.
Did you replace the tank sock?
Have you checked and cleaned the inside of the Fuel Filter Manager?
down inside of the bottom of the fuel filter housing is a small screen filter that can get clogged.
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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 08-30-2019, 10:13 PM   #6 (permalink)
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I left the sock off and put a 3/8 clear filter to catch any crap from the tank. Inside the fuel filter housing I cleaned the bottom and when ever I check it after the truck stalls, there seems to be only a quarter of diesel inside there. When I prime the pump, diesel begins to fill up inside the fuel housing, I just don't know if it's not getting enough diesel and why the engine idles rough and stalls. Very stressful, many hands on this truck and still can't run right. Thanks for the feedback guys.
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Old 08-30-2019, 10:57 PM   #7 (permalink)
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Quote:
Originally Posted by Mdifed View Post
I left the sock off and put a 3/8 clear filter to catch any crap from the tank. Inside the fuel filter housing I cleaned the bottom and when ever I check it after the truck stalls, there seems to be only a quarter of diesel inside there. When I prime the pump, diesel begins to fill up inside the fuel housing, I just don't know if it's not getting enough diesel and why the engine idles rough and stalls. Very stressful, many hands on this truck and still can't run right. Thanks for the feedback guys.
I would apply a 12v. jumper wire to the lift pump relay to force prime the fuel system and see if it improves.
( as shown here): https://www.dieselplace.com/forum/63...ml#post6910025

If it improves then I would look into replacing the OPS ( Oil Pressure switch) and test and or replace the lift pump relay located in the fuse box under the hood.
Go through all grounds as well

Also, install a piece of clear fuel line on the return side of the Injection Pump to help locate any air in fuel gremlins:
https://www.dieselplace.com/forum/63...ml#post7305306
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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


Last edited by OkDually; 08-30-2019 at 10:58 PM.
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Old 08-31-2019, 11:21 AM   #8 (permalink)
JMJNet
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Which Lift Pump did you put on?
May be there is not enough power with the addition of fuel filter?
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PMD in Bumper
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4" Warpspeed Exhaust
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Heath Turbo-Master
AD244 Alternator
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Old 09-02-2019, 11:10 PM   #9 (permalink)
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I bought a $55 lift Pump from autozone. I bleeded the fuel housing air and bled the air out of the t valve 2 days ago. Today I drove the truck for an hour without it stalling, although I wasn't giving it gas all the time, i was keeping a steady paste (2,000rpm) My mechanic told me I should get new lines that way the fuel can travel faster to the fuel housing and there will be more diesel to feed the injector pump. I feel that not enough diesel gets to the fuel housing when I gun it, so the truck shuts off because there isn't enough fuel reaching. Im not sure why there isn't enough diesel reaching to the fuel housing, possibly bad line? cracked rubber hose in lines? What do you guys think I should do?
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Old 09-03-2019, 09:48 AM   #10 (permalink)
jnlperformance
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The OEM setup is quite sufficient for a stock engine. (As far as fuel delivery is concerned)

I only skimmed ^^^ all that up there.

You have the correct fuel cap? The incorrect cap can strain fuel delivery.

I would have left the correct diesel tank sock. The lp is designed for that. Lift pumps push better than they pull.

If you have or you suspect you have major debris or corrosion in the tank you should pull the tank. Empty it. Rinse it out and let it bake in the sun to dry (if the tank is recoverable) if not replace the tank.

Disconnect line to fuel filter housing. Disconnect return line. Disconnect lift pump on both sides. Blow all lines out with compressed air while tank is dropped.

Install a new fuel filter in the ffm if you have not already.

With the truck running... open the air bleed valve on top of the filter. Does the engine struggle to run? Stall? Or does it pump fuel out just fine. Use a clear hose and a Jerry can so you can see if you have air bubbles present and if they are constant or if they go away.

If the engine stalls or has trouble running when the bleed valve is open the lp is weak and failing or was never strong enough to begin with. I always recommend the delco lp.

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Last edited by jnlperformance; 09-03-2019 at 10:14 AM.
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