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Old Yesterday, 02:09 PM   #1 (permalink)
SplitSsss
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Fuel issues help

Ok. 6.5 project.
Replaced lift pump, filters, injectors etc. All good up to the bleeder. Clean flow with no air. Problem. No fuel to the injectors. Rear four injector line cracked open. Nothing. Lots of cranking but nothing.
I need a little help understanding how the injector pump works. Tips on troubleshooting etc.

Truck project specs in my profile.

__________________
2000 GMC Savana 3500
former gasser now has an 01' 6.5L 4L80E

Stock block and heads. Leroy Diesel upgrades: Harmonic Bal and billet pully, Carter LP w/ remote prime switch, GM thermostats, New stock GM injectors.

New Oil lines, PMD re-location. Wicked Wheel, GloShift trans, boost, EGT gauges. Dual Alternators/batterys.
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Old Yesterday, 02:29 PM   #2 (permalink)
OkDually
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Go through all of your grounds using the link in the FAQ for reference.
Remove each one, clean and reinstall.

Try another "Known Working" PMD w/resistor installed.
Also try both PMD's on the OEM harness on the IP to rule out a bad extension harness.

__________________
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 Winter Formula


Proud member #1039 of The 3500 Dually Club


Last edited by OkDually; Yesterday at 02:30 PM.
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Old Yesterday, 02:40 PM   #3 (permalink)
Glagulator
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What was the donor vehicle?
Have you dealt with the factory security system?
__________________
There are 10 kinds of people in this world; Those who understand binary and those who don't.

99 CREW LONG SRW C3500 work truck 199k+ mi. orig. motor & trans 4.10, modded engine harness, new oil cooler & lines, all new front end parts and poly bushings, trans poly mount, all new brakes.
96 SUBURBAN K2500 wife's truck 210k+ mi. orig. motor & trans, 3.73...
95 C2500 Suburban 6.5td HO w/p, timing set, HB & pulley, all rubber hoses, modded engine & main harness, converted to OBD2, PMD to bumper...
95 C1500 Suburban 6.5td rebuild tranny, convert to DB2, replacing as many parts as I can.
96 C2500 Suburban 7.4L converting to 6.5td w/ DB2, 4L80, 3.73
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Old Yesterday, 04:23 PM   #4 (permalink)
SplitSsss
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Going through the grounds. The PMD and extension were good before the swap. No security system.
Any place to jump a direct ground for testing?
__________________
2000 GMC Savana 3500
former gasser now has an 01' 6.5L 4L80E

Stock block and heads. Leroy Diesel upgrades: Harmonic Bal and billet pully, Carter LP w/ remote prime switch, GM thermostats, New stock GM injectors.

New Oil lines, PMD re-location. Wicked Wheel, GloShift trans, boost, EGT gauges. Dual Alternators/batterys.
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Old Yesterday, 04:25 PM   #5 (permalink)
SplitSsss
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Exactly how does the injector pump run/work?
__________________
2000 GMC Savana 3500
former gasser now has an 01' 6.5L 4L80E

Stock block and heads. Leroy Diesel upgrades: Harmonic Bal and billet pully, Carter LP w/ remote prime switch, GM thermostats, New stock GM injectors.

New Oil lines, PMD re-location. Wicked Wheel, GloShift trans, boost, EGT gauges. Dual Alternators/batterys.
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Old Yesterday, 04:34 PM   #6 (permalink)
OkDually
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Quote:
Originally Posted by SplitSsss View Post
Going through the grounds. The PMD and extension were good before the swap. No security system.
Any place to jump a direct ground for testing?
You must rule those out to be absolutely sure.
A PMD can go bad very quickly.

GM installed a Theft Deterrent system on all 97+ year vehicles.
Here is a thread on the anti theft relearn:
https://dieselplace.com/forum/showth...141#post341141
__________________
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 Winter Formula


Proud member #1039 of The 3500 Dually Club

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Old Yesterday, 04:39 PM   #7 (permalink)
OkDually
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Quote:
Originally Posted by SplitSsss View Post
Exactly how does the injector pump run/work?
The electronic DS4 IP uses the PMD for monitoring the fuel solenoid open and close times and reports it to the ECM.
IF the PMD is bad you will have a no-start condition.

Also, remove the plunger from the fuel shutoff solenoid:
https://www.dieselplace.com/forum/63...ml#post5082905
__________________
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 Winter Formula


Proud member #1039 of The 3500 Dually Club

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Old Yesterday, 08:41 PM   #8 (permalink)
SplitSsss
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All good stuff. Grounded the PCM with a wire from ground to the heat sink. Looks like this may have helped. Getting a little fuel drip at the injectors. Battery needs charging so I’ll try again tomorrow.
__________________
2000 GMC Savana 3500
former gasser now has an 01' 6.5L 4L80E

Stock block and heads. Leroy Diesel upgrades: Harmonic Bal and billet pully, Carter LP w/ remote prime switch, GM thermostats, New stock GM injectors.

New Oil lines, PMD re-location. Wicked Wheel, GloShift trans, boost, EGT gauges. Dual Alternators/batterys.
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Old Yesterday, 09:00 PM   #9 (permalink)
Glagulator
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Join Date: May 2005
Location: Very south TEXAS, Formerly Wisconsin
Posts: 3,754
iTrader Score: 5 reviews

How did you deal with security?
__________________
There are 10 kinds of people in this world; Those who understand binary and those who don't.

99 CREW LONG SRW C3500 work truck 199k+ mi. orig. motor & trans 4.10, modded engine harness, new oil cooler & lines, all new front end parts and poly bushings, trans poly mount, all new brakes.
96 SUBURBAN K2500 wife's truck 210k+ mi. orig. motor & trans, 3.73...
95 C2500 Suburban 6.5td HO w/p, timing set, HB & pulley, all rubber hoses, modded engine & main harness, converted to OBD2, PMD to bumper...
95 C1500 Suburban 6.5td rebuild tranny, convert to DB2, replacing as many parts as I can.
96 C2500 Suburban 7.4L converting to 6.5td w/ DB2, 4L80, 3.73
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Old Yesterday, 09:03 PM   #10 (permalink)
OkDually
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Quote:
Originally Posted by SplitSsss View Post
All good stuff. Grounded the PCM with a wire from ground to the heat sink. Looks like this may have helped. Getting a little fuel drip at the injectors. Battery needs charging so Iíll try again tomorrow.
Take your batteries down to the local auto parts store and ask the staff to Individually Load Test them.
If one or both fail, replace them both as a matched set.

If you need to open injector lines only open the #1 line to lessen the amount of air you are introducing into the fuel system.

__________________
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 Winter Formula


Proud member #1039 of The 3500 Dually Club

Offline   Reply With Quote Quick reply to this message
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