Engine Controls - Tests W/o Codes - 6.5L Diesel: Other Chevrolet Pickup K2500

Possible Cause

No voltage to fuel shut-off solenoid.

Correction

Check electrical connections.

Restricted air filter.

Check and/or replace air filter.

Faulty glow plugs, relay or PCM.

Check and/or replace glow plugs or controls.

Plugged fuel return system.

Remove restrictions.

No fuel to nozzles.

Inspect fuel delivery system.

No fuel to injection pump.

Inspect fuel delivery system.

Clogged fuel tank filter.

Replace filter. See SYSTEM/COMPONENT TESTS - 6.5L DIESEL article in the ENGINE PERFORMANCE section.

Incorrect or contaminated fuel.

Remove and replace fuel.

Incorrect pump timing.

See appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section below.

1. «TESTS W/CODES - 6.5L DIESEL»(ref-19760) (for "C" & "K" Series)
2. «TESTS W/CODES - 6.5L DIESEL»(ref-19761) (for "G" & "P" Series)

Incorrect slow idle.

See appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section below.

1. «TESTS W/CODES - 6.5L DIESEL»(ref-19760) (for "C" & "K" Series)
2. «TESTS W/CODES - 6.5L DIESEL»(ref-19761) (for "G" & "P" Series)

Faulty fast idle solenoid.

Replace solenoid. Proceed to appropriate SYSTEM/COMPONENT TESTS - 6.5L DIESEL article in the ENGINE PERFORMANCE section.

Plugged fuel return system.

Remove restrictions.

Glow plugs turn off too soon.

Check glow plug system. Proceed to appropriate SYSTEM/COMPONENT TESTS - 6.5L DIESEL article in the ENGINE PERFORMANCE section.

Limited fuel to injection pump.

Check fuel delivery system.

Air in injection lines to nozzles.

Check line fittings.

Incorrect or contaminated fuel.

Remove and replace fuel.

Faulty injection pump.

Replace pump. See appropriate N - REMOVE/INSTALL/OHAUL

article in the ENGINE PERFORMANCE section below.

1. «REMOVE/INSTALL/OVERHAUL»(ref-19770) (for "C" & "K" Series)
2. «REMOVE/INSTALL/OVERHAUL»(ref-19771) (for "G" & "P" Series)

Fuel shut-off solenoid closes in RUN position.

Check solenoid operation. Proceed to appropriate SYSTEM/COMPONENT TESTS - 6.5L DIESEL article in the ENGINE PERFORMANCE section.

TCC stuck on.

Check brake switch and PCM control.

Leaking injection line.

Check fittings and/or replace line.

Plugged fuel return line.

Remove restrictions.

Air in lines to nozzles.

Check line fittings.

Air in injection pump.

Check pump fittings and pump operation.

Faulty nozzle.

Replace nozzle. See SYSTEM/COMPONENT TESTS - 6.5L DIESEL article in the ENGINE PERFORMANCE section.

Improper or contaminated fuel.

Remove and replace fuel.

Uneven fuel distribution.

Check fuel delivery system.

Incorrect pump timing.

See appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section.

1. «TESTS W/CODES - 6.5L DIESEL»(ref-19760) (for "C" & "K" Series)
2. «TESTS W/CODES - 6.5L DIESEL»(ref-19761) (for "G" & "P" Series)

Restricted air filter.

Check and/or replace air filter.

Air in injection lines to nozzles.

Check fittings on lines.

Faulty nozzle.

Replace nozzle. See SYSTEM/COMPONENT TESTS - 6.5L DIESEL article in the ENGINE PERFORMANCE section.

Improperly installed high pressure lines.

Remove lines, and reinstall properly.

Misrouted or kinked vacuum lines.

Check lines, and reinstall properly.

Faulty EGR operation

Check EGR system.

Faulty charging system.

Check alternator output.

Faulty PCM operation.

See appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section.

1. «TESTS W/CODES - 6.5L DIESEL»(ref-19760) (for "C" & "K" Series)
2. «TESTS W/CODES - 6.5L DIESEL»(ref-19761) (for "G" & "P" Series)

Faulty TCC or shift points.

Check transmission operation.

Loose or broken fuel line or connection.

Check all fuel line fittings, and correct as necessary.

Internal seal leak in injection pump.

Remove and replace injection pump.

Restricted air intake.

Remove restrictions.

Plugged fuel filter.

Remove restriction and/or replace filter.

Faulty PCM operation.

See appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section.

1. «TESTS W/CODES - 6.5L DIESEL»(ref-19760) (for "C" & "K" Series)
2. «TESTS W/CODES - 6.5L DIESEL»(ref-19761) (for "G" & "P" Series)

Improper fuel return system.

Check fuel return system.

Restricted tank-to-pump fuel supply.

Check fuel delivery system.

Incorrect or contaminated fuel.

Remove and replace fuel.

Faulty EGR operation.

Check EGR system.

Worn camshaft or valves.

Check compression and valve lift.

Nozzle or glow plug compression leaks.

Check fittings, and replace as required.

Plugged nozzle.

Remove restriction and/or replace nozzle.

Faulty TCC or shift points.

Check transmission operation.

Air in fuel system.

Check fuel delivery system for leaks.

Air in high pressure lines.

Check fittings for leaks.

Incorrect pump timing.

See appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section.

1. «TESTS W/CODES - 6.5L DIESEL»(ref-19760) (for "C" & "K" Series)
2. «TESTS W/CODES - 6.5L DIESEL»(ref-19761) (for "G" & "P" Series)

Nozzle sticking in open position.

Inspect and/or replace nozzle.

Low nozzle opening pressure.

Check nozzle operation. Proceed to appropriate SYSTEM/COMPONENT TESTS - 6.5L DIESEL article in the ENGINE PERFORMANCE section.

Faulty ECT sensor.

Check sensor operation. Proceed to appropriate SYSTEM/COMPONENT TESTS - 6.5L DIESEL article in the ENGINE PERFORMANCE section.

Incorrect pump timing.

See appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section below.

1. «TESTS W/CODES - 6.5L DIESEL»(ref-19760) (for "C" & "K" Series)
2. «TESTS W/CODES - 6.5L DIESEL»(ref-19761) (for "G" & "P" Series)

Incorrect pump housing pressure.

Check pump for internal leaks.

Defective injection pump.

Replace injection pump. Proceed to appropriate SYSTEM/COMPONENT TESTS - 6.5L DIESEL article in the ENGINE PERFORMANCE section.

Injection pump fuel shut-off solenoid does not return to off position.

Check solenoid operation. Proceed to appropriate SYSTEM/COMPONENT TESTS - 6.5L DIESEL article in the ENGINE PERFORMANCE section.

Engine Lacks Power

Check probable causes No. 1, 3, 4, 6-11 and 16-21.

Black Smoke

Check probable causes No. 2-4, 6-11 and 16-20.

Blue Smoke

Check probable causes No. 2, 6-8, 13-15 and 17-20.

Excessive Oil Consumption

Check probable causes No. 2, 6-8, 13-15 and 17-20.

Cyclic Sound From Turbocharger

Check probable causes No. 2, 19 and 20.

Oil Leak At Turbine Seal

Check probable causes No. 13-15 and 17-20.

Oil Leak At Compressor Seal

Check probable causes No. 2, 8-11, 13-15 and 17-20.

PROBABLE CAUSES

1. Clogged air filter element.
2. Obstructed air intake duct to turbo compressor.
3. Obstructed air outlet duct from compressor to intake manifold.
4. Obstructed intake manifold.
5. Air leak in duct from air cleaner to compressor.
6. Air leak in duct from compressor to intake manifold.
7. Air leak at intake manifold-to-engine joint.
8. Obstruction in exhaust manifold.
9. Obstruction in exhaust system.
10. Gas leak in exhaust manifold-to-engine joint.
11. Gas leak in turbine inlet-to-exhaust manifold joint.
12. Gas leak in ducts after turbine outlet.
13. Obstructed turbocharger oil drain line.
14. Obstructed engine crankcase ventilation.
15. Turbocharger center housing sludged or coked.
16. Engine camshaft timing incorrect.
17. Worn engine piston rings or liners (blow-by).
18. Internal engine problems (valves, pistons).
19. Dirt caked on compressor wheel and/or diffused vanes.
20. Damaged turbocharger.
21. Wastegate stuck open.

Intermittent Simulation

Use following methods to reproduce conditions causing intermittent.

1. Apply light vibration to components.
2. Heat component.
3. Wiggle or bend wiring harness.
4. Spray component with water.
5. Remove/apply vacuum supply source.

Monitor circuit/component voltage or resistance while attempting to simulate intermittent. If vehicle is running, monitor for self-diagnostic codes. Use test results to identify faulty component or circuit.

Possible Causes & Corrections

Use following procedures to determine possible causes of intermittent Malfunction Indicator Light (MIL) operation.

1. Check for poor mating of one connector to another. Terminals may not be fully seated. Check for improperly formed or damaged terminals. Check wire-to-terminal connections.
2. Check for poor connection from ignition coil to ground or arcing at spark plug wires or plugs.
3. Check wire from Malfunction Indicator Light (MIL) to PCM for short to ground.
4. Check wire from Data Link Connector (DLC) test terminal for intermittent short to ground.
5. Check for poor connections in PCM ground terminals.
6. Check for loss of trouble code memory. To check code, disconnect TP sensor, and run engine at idle until Malfunction Indicator Light (MIL) comes on. Code 22 should be stored and retained in memory when ignition is turned off. If not, PCM is faulty.
7. Check for electrical system interference caused by defective relay, PCM-driven solenoid or switch, which may cause sharp electrical surge. This type of problem will normally occur when faulty component is operated.
8. Check for aftermarket parts which may not have been produced to manufacturers' specifications. Solenoids without original-equipment diodes for circuit protection and HEI-EST module or voltage regulator using transistors instead of silicone-chip circuitry may cause voltage surges (up to 300 volts) in PCM wiring, causing temporary PCM shutdown. PCM shutdown is a normal response to system overvoltage (over 16 volts on most models). PCM repowers when condition ceases to exist. A rapid shutdown and repower could cause a flickering Malfunction Indicator Light (MIL) with no codes set in memory.
9. Check for improper installation of electrical accessories such as auxiliary lights or 2-way radios.
10. Ensure EST wires are kept away from spark plug wires, distributor wires, distributor housing, ignition coil and generator. Ensure ground wire from PCM to distributor or ignition module is connected to a good ground.
11. Check for intermittent short to ground on terminal "B" (diagnostic enable) of Data Link Connector (DLC) or in Malfunction Indicator Light (MIL) circuit.
12. On vehicles not equipped with a driver information center, use scan tester to check for intermittent wiring problem. See SCAN TESTER USAGE in appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section.
13. «TESTS W/CODES - 6.5L DIESEL»(ref-19760) (for "C" & "K" Series)
14. «TESTS W/CODES - 6.5L DIESEL»(ref-19761) (for "G" & "P" Series)