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6.5L Turbo Diesel 1992-00 6.5L Turbo Diesel - Welcome to the Internet's first discussion forum for the 6.5L diesel engine. Tips on performance, upgrades, cooling, fuel economy, troubleshooting and more.

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Old 03-22-2006, 08:03 AM
6.6/6.5 6.6/6.5 is offline
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Default New 6.5 Owner - Engine Misfiring

I'm a new 6.5 owner ('95 Silverado) and a new member of TDP (first post). I purchased the p/u knowing that it had engine issues. The price was low enough and the body/chassis is in good shape, so the engine issues were an acceptable risk. I have searched the archives of this forum without finding a definitive answer to several questions.

First, the engine is misfiring on at least one cylinder. I will attempt to identify the specific cylinder, but I believe that it is valve related (collapsed lifter?). Besides a collapsed lifter, broken rocker arm retainer or malfunctioning injector, what other sources of engine misfiring are applicable to the 6.5 Turbo Diesel?

Second, the engine (long block, not the accessories) is painted yellow. I suspect the engine has been remanufactured or has been provided by an volume overhaul enterprise. Does the yellow paint indicate a specific company or organization that did the remanufacturing/overhauling? If the company can be identified by the paint, does anyone have a comment about the quality of their work?

I have found TDP and this forum to very informative and I appreciate the value of my TDP membership. Likewise, I will be very appreciative for any answers that might be provided for my questions.
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'03 2500HD - 6.6 Duramax - CrewCab - 4X4 - 6.5' Box
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  #2  
Old 03-22-2006, 10:41 AM
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trbankii trbankii is offline
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The "easiest" problem that could cause a "misfire" is air in the injector lines. Hard to say without listening to it, but I'd try bleeding them out. Sounds sort of unlikely if it is just one line - unless someone opened it for some other reason and let air into it.
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  #3  
Old 03-22-2006, 12:42 PM
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john8662 john8662 is offline
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I remember this truck on ebay (if you found it there).

The engine was painted yellow, and so were some of the engine components (part of the pump, some of the lines, etc.). To me, it was a sloppy paint job right before putting the engine in the truck.

I had my doubts that the engine was fully rebuilt, more like it was taken apart and repaired.

You've hit the highlights of the minor problems that could cause a misfire.

Collapsed lifter, broken retainer on rocker.

Other things to consider would be a failed injector.

The first thing you should do with this engine is purchase a diesel compression tester with the appropriate adapter for a 6.5 and do a complete compression test on the engine.

Get the engine up to normal operating temp, remove the "fuel sol" fuse from the fuse box under the hood (to keep it from starting). Remove a glow plugs, insert you adapter, and connect gauge. have helper crank over the enigne (with fully charged batteries and great working starter) and count 6 puffs on the gauge, the final amount is your compression for that cylinder.

Report back.
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Old 03-23-2006, 07:41 AM
6.6/6.5 6.6/6.5 is offline
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John,

Thank you for the response to my posting. Yes, the p/u was purchased on eBay from a Utah auction firm. The body, chassis and drive train seem to be in very good condition, but the engine is problematic. I need a work truck and it will serve my purposes very well once the engine issues are resolved. I ordered a compression gage and adapter last night and I will report the compression data as soon as they are measured.

Some additional symptoms: The engine smokes heavily (blue smoke) on starting. The smoke clears approximately 2 to 3 minutes after starting. There is oil in the induction hose between the filter housing and the turbocharger. I will replace the CDR as soon as one can be purchased. The engine produces a "clicking" sound at idle. This noise either stops or is masked with higher engine speeds. Probing with a stethoscope didn't provide any definitive information, but there does seem to be a slight increase in the volume of the metallic clicking sound in the proximity of the No. 6 cylinder.

Besides servicing the fluids and filters, I've replaced the glow plugs which has made the starting much better.

Jim
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'03 2500HD - 6.6 Duramax - CrewCab - 4X4 - 6.5' Box
'95 K2500 - 6.5 Turbo Diesel - Std. Cab - 8' Box
'76 Caterpillar D6C - 3306 Cat Diesel - Straight Blade
'66 Case 430 Utility - 188 Diesel - Ldr. & Backhoe
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  #5  
Old 03-23-2006, 09:19 AM
BobND BobND is offline
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As for the CDR, there's a 90+ % chance the oil in the hose is simply from oil mist condensing out of the engine blowby simply passing through the CDR, as it is supposed to.

The CDR is basically an open, empty chamber with a spring-loaded diaphragm that begins to close off the crankcase ventilation flow if the crankcase pressure begins to go negative.

Realistically, the only time that would happen is with a restricted air filter, or POSSIBLY on an engine in very good condition, with very little blowby, at high RPM's (LOTS of air being drawn in by the turbo.

The CDR's that I have replaced were replaced because the diapragm developed a leak, and oil leaked EXTERNALLY through the tiny weekhole in the side of the CDR.
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Old 03-23-2006, 10:30 AM
moondoggie moondoggie is offline
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Good Day!

When does it miss? All the time? cruising? Heavy footfeed?

Blessings!
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Old 03-23-2006, 11:50 AM
6.6/6.5 6.6/6.5 is offline
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The engine misses most noticeably at idle. However, I am quite certain that it continues to miss at higher engine speeds. The clicking noise can be readily heard at idle, but is still detectable up to 1500 rpm when the exhaust and combustion noises tend to be more apparent.
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'03 2500HD - 6.6 Duramax - CrewCab - 4X4 - 6.5' Box
'95 K2500 - 6.5 Turbo Diesel - Std. Cab - 8' Box
'76 Caterpillar D6C - 3306 Cat Diesel - Straight Blade
'66 Case 430 Utility - 188 Diesel - Ldr. & Backhoe
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  #8  
Old 03-23-2006, 12:27 PM
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Could be a piece of detritis in one of the injectors. At higher power levels it has less effect. Loosening the fuel lines one cylinder at a time will isolate the offending cylinder, then you may want to have that injector tested.
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Old 03-26-2006, 09:18 AM
gvig gvig is offline
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I purchased a warranty pull out (6.5) that had this very problem, finally found a broken valve spring. When you isolate the cylinder and find no compression at idle speeds, check the valve springs, a valve will float open without enough spring pressure, but the compression pressure at high rpms will blow it shut.

Good luck!
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Old 03-27-2006, 04:43 PM
6.6/6.5 6.6/6.5 is offline
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The following is a report on the compression test. The Matco compression gage and adapter arrived today and the following data were measured:

No. 1 = 330 psi No. 2 = 340 psi
No. 3 = 290 No. 4 = 340
No. 5 = 300 No. 6 = 320
No. 7 = 310 N0. 8 = 220

No. 8 was the first cylinder tested so it had the advantage of a more warm engine than the remaining cylinders (No. 1 was the last tested).

So, tomorrow the intake manifold and rocker arm covers will be removed in an attempt to determine what ails cylinder #8. Given the relatively low compression readings, I suppose that I should be contemplating a "drop-in" remanufactured engine or pulling and overhauling the existing engine. The truck's condition warrants a decent engine. I'll do some trouble shooting first.
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'03 2500HD - 6.6 Duramax - CrewCab - 4X4 - 6.5' Box
'95 K2500 - 6.5 Turbo Diesel - Std. Cab - 8' Box
'76 Caterpillar D6C - 3306 Cat Diesel - Straight Blade
'66 Case 430 Utility - 188 Diesel - Ldr. & Backhoe
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