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Discussion Starter · #1 · (Edited)
Update: injection pump was the problem.


VIN 5B4KP42Y033368329
2003 Workhorse p42 NON-turbo 6.5 diesel

Hello all, long time lurker but just joined... the truck is a retired USPS stepvan bought from govdeals about 2 years ago..it was running ok until recently. I have read a few posts that had similar problem but the Original Posters have not shared what had repaired their issues.

The video makes it seem like I am letting off the pedal but I'm not. Also, when I try to accelerate, it sprays a lot of black smoke from the exhaust.

It had a P0251 code = injection pump fuel metering control "A" and I cleared it and it has not returned after over 100 miles.

I have already replaced the Dorman 904-104 PMD module that's mounted remotely and changed the oil.

I still need to replace the fuel filter.

Here is the video:


I am not sure what's next. I'm afraid it's an injector problem but I wanted to pick your brains before I go that route since the connections are very rusted.
 

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Discussion Starter · #5 ·
Replaced fuel filter, air filter.

Added diesel clean to the bowl, let it idle for 2 min and shut it off for 30 min

NO CHANGE.

I noticed it is worse once the engine is warm.
When I floor it WOT at 35mph, there's no power, it does accelerate but smokes terribly (black smoke).

It sounds like the same problem in this thread:


Not sure what to do next, I use this truck for my plumbing business and just thinking about selling it at this point.
 

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Discussion Starter · #9 ·
I will check the grounds and install the clear tube today.
The IP is hard to get to in the step van.
Is there anywhere I can install a fuel gauge on?

There are no issues at idle but it will smoke if I raise the RPMs.

The SES light is due to P0380 Glow/Plug Heater Circuit A because one of the connectors has corroded off. The truck still starts OK.

Seems like another one here with a similar issue. Asked him to update with his findings:
 

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Discussion Starter · #12 ·
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Unfortunately no change after cleaning the grounds.
There was no air bubbles in the clear tube.

I dont have a stalling issue.

In Park, I cannot gradually raise the RPMs, it just jump up to ~3k suddenly, then comes back down to normal idle. Today it idled rough after a couple high revs, I shut it off, restarted and it started idling fine.

I checked the solenoid and it plunges fine. Anything else I can check before I go after the IP and injectors?

Passenger side lines are corroded so I'll probably have to replace those as well.
 

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Discussion Starter · #14 ·
OK. The van only has 60k miles. Surprised it would go bad at this low of a mileage.. i guess I'll have to order one.
 

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Discussion Starter · #16 ·
I am not sure. I will check. I don't know what GM engine year these 6.5L non-turbo is compatible with.

Would unleaded fuel mixed with diesel cause the issues I am having? I remember it started happening after I filled it up.
 

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Discussion Starter · #18 ·
Gasoline mixed with diesel...not sure what would happen but, it wouldn't be good. If you suspect this, I would drain all the fuel and start over. Additionally, if you have an EGR valve, it be in the center of the air cleaner once you remove the air cleaner lid. Should have a round vacuum diaphragm on a cast iron base.
I'll drain, put everything back together and start over...
I'm thinking I should at least replace the injectors while I have the top apart and replace the fuel lines as well.

I do not have an EGR valve as shown in this picture:
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Discussion Starter · #20 ·
Quick update:

Replaced all injectors, lifter pump, fuel filter and fuel lines... Still doing the same thing.
I bought a Stanadyne Reman pump from D&W Diesel, which is going in today&tomorrow.
 

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Discussion Starter · #21 ·
It was the injection pump !

The replacement was very straightforward, the worst part were all the injector lines and the lower bolt by the passenger side.

Thank you for all the help. I will update the YouTube video description with a link to this thread.
 
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