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6.5L Turbo Diesel - Tech Support - Troubleshooting - Performance 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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  #1  
Old 02-16-2020, 02:11 PM
Lightyear Lightyear is offline
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Default The '99 Burb cranks, smokes, no start

Hello everyone

After sitting for about four weeks since the last stranding episode I stared tinkering with the Burb. She'll crank at starting speed, build about 30 psi oil pressure, almost fire, but not start.
So far, have done the following:
2 new batteries
New Stanadyne gray PMD from Kennedy
Cleaned filter manager
Replaced and bled new GM filter
Checked flow at IP inlet, good fuel no bubbles
Glow seems good, I can watch the voltmeter cycle with the key at on
Attempted start with optical sensor disconnected
Cracked open injector lines 1, 2, 3, 5, 6, and 7...fuel at each of those cylinders. (Can't reach 4 and 8)
It ran until I parked at long term parking for about 8 days, then would crank but not start. It feels closer to starting now, it'll buck and catch for a few seconds but not run, it has gotten to around 500rpm while trying and coughing. Gray smoke at tailpipe.

Any suggestions?

Thanks!
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'99 K2500 'Burb, my DD
301K
K&N insert in stock airbox
Relocated PMD behind front bumper

Last edited by Lightyear; 02-16-2020 at 02:12 PM. Reason: forgot to add a statement
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Old 02-17-2020, 09:10 AM
joed joed is offline
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Default Resistor in new FSD?

Does your new gray FSD from Kennedy have a resistor in the connector cavity? My friend just went through this on his 98. His truck would start but run very roughly, like it was missing on more than one cylinder. He installed the resistor from his old FSD, and now it runs great with the gray one. Just a thought. Joe.
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Old 02-17-2020, 09:48 AM
Lightyear Lightyear is offline
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Default

Joe -

Yep, I bought a new #5 from JK when I got the PMD. Have been working my way down the troubleshooting guide in the GM manual, will have some updates to the story shortly...

Thanks for the suggestion!
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Buzz
'99 K2500 'Burb, my DD
301K
K&N insert in stock airbox
Relocated PMD behind front bumper
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Old 03-15-2020, 08:53 AM
phantom309 phantom309 is offline
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Things that have caught me before,.
After installing new batteries glow plugs only cycle for a second or two until there has been an attempt to start.
Relay for glow plugs has stuck on an fried glow plugs,.
Stepper motor has given up on the ip and won't give enough timing to start nicely,.
In you case i would pull the 2-3 easy glow plugs on drivers side and use booster cables to verify they are heating up.
Try plugging it in too,. See if it will fire then go from there
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Old 03-25-2020, 07:53 PM
Lightyear Lightyear is offline
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She's alive!! Turns out it was a bad female end on the 4-pin harness from the IP to the PCM. Went back to troubleshooting 101...had glow for sure, air as well, but no fuel. I mucked around with that pigtail connection while cranking and it coughed, almost started. Unplugged, forced the leads a bit further into the connector, re-connected and bang she fired. Found a replacement female end at connectorexpertsdotcom, whom I recommend. There site has a million parts, but of you send photos of either end you need they will match it if they have it. Two FedEx days later I was driving the old beast again.
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Buzz
'99 K2500 'Burb, my DD
301K
K&N insert in stock airbox
Relocated PMD behind front bumper
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  #6  
Old 03-26-2020, 05:22 PM
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JohnC JohnC is offline
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Outstanding!
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