2000 6.5L Diagnostics on PDF
Contents
1. OREGON FUEL INJECTION INC 6 5L DS Pump Diagnostics To properly diagnose a 6 5L vehicle with the DS model pump you will need a scan tool The 1994 and 1995 are OBD1 and the 1996 through the 2000 model year is OBD2 so the diagnostic codes are different depending on the year range LOW POWER 1 Low or no fuel supply pump pressure 2 Dirty fuel filter 3 Wastegate control solenoid WHITE SMOKE 1 Low or no fuel supply pump pressure 2 Retarded timing use Tech 2 scan tool to perform TDC offset learn procedure We normally set the timing to 1 to 1 5 degrees BLACK SMOKE 1 Dirty air filter Waste gate control solenoid failure or low vacuum Worn injectors excess carbon on the nozzle tips Low or no fuel supply pump pressure If this occurred after the plenum chamber intake was removed check the EGR tower gasket if not seated EGR gases enter the intake unrestricted and in excessive quantity 6 Restricted exhaust system if the vehicle has been babied the cat will partially plug Take the vehicle outfor several full throttle accelerations to clear out the exhaust ae ws HARD START HOT 1 Ifthe complaints ahard start after a hot soak not a stalling condition then hard start check for a minimum cranking speed hot of 200 rpm MISS 1 Worn injectors 2 If the engine was overheated check for a head gasket problem usually on the turborside usually 4 amp 6 3 See Misfire Codes further below NOSTART DIE2. active DTC s 35 or P1216 refer to Engine Controls in the 1998 Service Manual for all model years If the DTC diagnostic table flow chart directs you to replace the injection pump replace the PMD Pump Mounted Driver which is also called the Fuel Solenoid Driver Go to step 9 7 For stall condition disconnect the Optical Sensor Encoder Sensor and operate the engine in back up mode you will experience an extended crank time during starting up to 15 seconds A bad noise suppression harness or no noise suppression harness can also cause a stalling condition If the condition is still present replace the PMD only Go to step 9 8 For a no start condition check injection pulse width 94 95 or C Time 96 2000 Fuel Solenoid Closure Time with a scan tool while cranking maintain minimum cranking speed 100 rpm cold and 200 rpm hot If C Time is 1 95ms 94 95 or 0 01ms 96 2000 replace the PMD Go to step 9 9 Replacing the PMD The PMD must be mounted to a heat sink of some kind Stanadyne Injection Pump Manufacture states that the PMD must be mounted to the injection pump with the heat pad underneath it In order to mount the PMD to the injection pump you must remove the intake manifold If you don t want to remove the intake manifold you could purchase a EUGENE 4036 West 1 Ave Eugene OR 97402 541 485 1434 8 28 2015 www oregonfuelinjection com 3 OREGON FUEL INJECTION INC remote mount kit such as
3. the BD remote mount kit and an aftermarket PMD This would allow you to replace the PMD without removing the intake manifold Stanadyne has finally come out with a new PMD it is completely redesigned from the original PMD Since the wire harness connections are different as well as the calibration resistor the intake manifold must be removed in order to replace the PMD because the wire harness between the PMD and the Fuel Control Solenoid will have to be replaced Removing the PMD requires a T15 TORX bit Replace the heat transfer pad and use snap ring pliers to remove the calibration resistor Install the calibration resistor into the new PMD 1 Fuel Solan Driver Z Fuel Solencid Driver Galibraiing Aessior 3 Fusi Solenoid Drvar Calibrating Resistor identification Number 4 Fuel Solenoid Driver Calibrating Fiesistor index Match 5 Fuel Solenoid Driver Calibrating Resistor Removal Hons 5 kasta Nose Piers 7 Fae Solenad Dever index Netch for Calibrating Feasta If the calibration resistor is damaged there is an identification number on it 1 through 9 and we have them available IMPORTANT IF THE FUEL SOLENOID DRIVER CALIBRATING RESISTOR IS MISSING DTC 56 1994 1995 OR P1218 1996 1998 WILL SET EUGENE 4036 West 1 Ave Eugene OR 97402 541 485 1434 8 28 2015 www oregonfuelinjection com 4 Member Association of Diesel Specialists OREGON FUEL INJECTION INC INSTALL FUEL SOLENOID DRIVER Align t
4. ION INC 3 Bad connections in the harness connectors and or a bad noise suppression harness are common causes for this code DTC P1216 35 fuel solenoid response time too short 1 Sets if closure time is less than 1 2 ms or less than 75ms on later years 2 Commonly caused by bad PMD Check the PMD harness circuits for good voltage and grounds prior to replacing the PMD See PMD Replacement above 3 On some occasions this code can be set by a bad fuel solenoid in the injection pump DTC P1217 36 fuel solenoid response time too long 1 Closure time more that 2 5 ms 2 Can be caused by a weak fuel control solenoid bad PMD poor grounds low supply voltage at PMD See PMD Replacement above DTC P1218 56 Injection pump calibration resistor error 1 Usually is caused by a missing calibration resistor andsthis code sometimes will only set after attempting TDC offset learn DTC P1125 84 Accelerator Pedal Position Sensor System Performance 1 This code can set if your foot is onsthe throttle and brake when key is turned on DTC P1214 88 injection pump timing offset error 1 The pump to engine timing must be set within 2 02 to 2 02 degrees when doing TDC offset learn or this code will set You must reset timing rotate the pump clear the code and retry TDC offset learn 2 This code could also set if the starter was used to crank the engine over while installing the injection pump this will sometimes partially s
5. S INTERMITTENTLY OR STALLING This is often caused by a bad PMD Pump Mounted Driver or Fuel Control Solenoid Driver however it is unusual to have multiple failures of the PMD A bad Fuel control Solenoid part of the injection pump can cause the same symptoms and codes A bad EUGENE 4036 West 1 Ave LI LUA Eugene OR 97402 Member Association of Diesel Specialists 541 485 1434 8 28 2015 www oregonfuelinjection com 1 OREGON FUEL INJECTION INC EGR EGR vent wastegate control and transmission solenoid are on the same quad driver circuit and can cause intermittent stalling PMD pump mounted driver The pump mounted driver gets 12 volt power when the key is on from a fuse The PCM then sends a signal to the PMD to close the fuel control solenoid When the fuel control solenoid closes it sends a signal back to the PMD and that is relayed to the PCM The response time of the closure signal is called C time C Time should change slightly when the engine is accelerated or decelerated A fixed C gt Time can indicate a bad Fuel Control Solenoid If the C Time is erratic when the RPM is stable then this usually indicates a bad PMD See Wire Harness Testing for other possible problems See PMD replacement guideline below PMD REPLACEMENT GUIDELINE Prior to replacement of the PMD we use the following guidelines to determine if a PMD may need to be replaced This is a simple first step and is less in depth than the GM bulle
6. an set A missing or improperly sealing EGR tower gasket can cause either or both codes to set Low or no vacuum from the vacuum pump can also cause EGR codes to set A missing EGR tower gasket can cause a MAF low code to set along with excessive black smoke because it is pulling exhaust gases instead of clean air through the air filter Failure to remove the block off plates from the intake manifold gaskets for a light duty engine can cause EGR codes because there will be no exhaust gases getting to the EGR valve FUEL SUPPLY PUMP The supply pump operates during cranking and after the engine oil pressurescomes up The supply pump is driven from a relay on the firewall or in the under hood fuse relay center The oil pressure sensor also includes a switch to operate the supplyypump once oil pressure comes up after starting The supply pressure should be between 5 7 psi at idle Test at the fuel filter drain at the front of the engine near the coolant crossover Be aware that this is a test on the dirty side of the filter and if the filter is dirty the actual supply pressure to the injection pump will be lower If the fuel supply pressure is zero remove the fuel supply pump relay and jump 30 amp 80 connector this will send power to the supply pump with the ignition on If you have good supply pressure now then the most likely cause is a bad oil pressure sending switch Low supply pressure can cause DTC P0370 17 and P0251 18 to set d
7. d aipfilter or bad CDR valve can cause excessive oil to be pulled out of the engine and discharged from the turbo back into the intake If the silicone hose connecting the compressor discharge is not sealed with a minor amount of silicone sealant than the hose connection will weep oil past the hose WASTEGATE CONTROL SOLENOID The wastegate WG control solenoid controls the amount of vacuum going to the wastegate actuator on the turbo The WG solenoid is controlled via a pulse width modulated signal from the PCM WIRE HARNESS TESTING Poor electrical connections or wiring can cause most intermittent problems Perform a careful check of the suspected circuit for the following Inspect and ensure the integrity of all related wiring harness connectors If the wiring harness connectors are not properly put together or engaged before they are locked together numerous types of conditions may occur This may include many intermittent symptoms and DTC codes The first step in any type of electrical diagnosis is that a visual and physical inspection be completed of the wiring harness connectors for integrity Many times the vehicle may be repaired just by disconnecting and reconnecting the connectors As with all repairs to wiring harness connectors and terminals a pin test of the terminals within the connector should be performed A pin test is performed by inserting the proper size terminal test tool not a paper clip into the terminal to deter
8. dows in order to not set a code TDC OFFSET LEARN The pump to engine timing must be set with a scan tool You need to do the TDC offset learn procedure in order to set base pump to engine timing TURBO EUGENE F a 2 ey 4036 West 1 Ave 4 mn Eugene OR 97402 541 485 1434 8 28 2015 www oregonfuelinjection com 7 Member 9 Association of Diesel Specialists OREGON FUEL INJECTION INC The turbo on the 6 5L EFI engine has a wastegate actuator that is controlled by vacuum The wastegate actuator on the 94 2000 turbo does not have a spring when no vacuum is applied the wastegate will flop back and forth If the wastegate actuator holds a vacuum and it moves freely back and forth when no vacuum is applied then there is nothing wrong with the wastegate actuator A turbo boost problem and DTC P0236 78 is normally caused by low vacuum need 20 inches HG or a bad wastegate control solenoid To inspect the turbo remove the inlet hose from the compressor inlet and make sure the turbo spins freely and that the compressor wheel does not rub on the housing when pushed to the side Some side play is normal because the bearings float on oil when the oil pressure comes up after starting The turbo pulls crankcase fumes through the CDR valve It is normal for the turbo to discharge oil from the compressor housing You have to determine if you have more oil coming out versus going into the compressor housing A plugge
9. he mounting screws on the PMD with the holes on the injection pump or on the remote mount PMD heat sink Torque the mounting screws to 23 LB IN IMPORTANT DO NOT INSTALL THE FUEL SOLENOID DRIVER WITHOUT A NEW HEAT TRANSFER PAD DO NOT REUSE A HEAT TRANSFER PAD USE A NEW HEAT TRANSFER PAD ONLY THE HEAT TRANSFER PAD IS REQUIRED TO PREVENT RAPID FAILURE OF THE FUEL SOLENOID DRIVER FROM OVERHEATING NOTICE DO NOT OVER TIGHTEN FUEL SOLENOID DRIVER MOUNTING SCREWS DAMAGE TO THE FUEL SOLENOID DRIVER WILL RESUET For Other Starting Issues Check the high resolution signal cam signal from the injection pump and crank signal High Res x 0 x x x signal Cam signal x x 0 x 0 Crank signal 0 x 0 x Will it start Yes Yes Yes No Yes noisy extended on startup crank X good signal 0 no signal Hertz Readings HZ while cranking and at idle RPM 140 160 180 200 700 800 High Res 597 Hz 683 Hz 768 Hz 853 Hz 2987 Hz 3413 Hz Signal Cam and 9 Hz bl Hz 12 Hz 13 Hz 47 Hz 53 Hz Crank Signal EGR Light duty engines utilize an EGR system to help meet emissions The EGR flow calculation on some models uses the MAF sensor If there are any air intake leaks EUGENE 4036 West 1 Ave Eugene OR 97402 541 485 1434 8 28 2015 www oregonfuelinjection com 5 Association of Diesel Specialists OREGON FUEL INJECTION INC either MAF or EGR codes c
10. he solenoid is bad If the vacuum pump is not producing 24 of vacuum then there are either leaks or the pump itself is bad DTC P0251 18 injection pump cam sensor circuit optical sensor 1 Similar to P0370 see comments underDTC P0370 sets when cam reference counts are missed Can also be set by contaminated fuel or aerated fuel like P0370 2 Bad connections in the harness connectors and or a bad noise suppression harness are common causes for this code DTC P0335 19 crankshaft position reference error 1 Bad crank sensor or wiring issue DTCP0370 17 timing reference high resolution system performance optical sensor The optical sensor encoder cam is used by the injection pump to determine injection timing relative to engine position This code and the P0251 set when counts are missed from the pump cam but picked up from the engine crank position sensor The optical sensor can not be changed with the pump on the engine The pump has to be partially disassembled parts replaced and then tested on the test stand 1 Can be caused by aeration in the fuel from a plugged fuel filter low fuel supply pump pressure or low fuel level in fuel tank 2 Contaminated fuel or fuel with dyes in it Red off road fuel or automatic transmission fluid in fuel can also cause the optical sensor to miss counts EUGENE 4036 West 1 Ave Eugene OR 97402 541 485 1434 8 28 2015 www oregonfuelinjection com 9 OREGON FUEL INJECT
11. hear the crankshaft timing chain gear key EUGENE 4036 West 1 Ave Eugene OR 97402 541 485 1434 8 28 2015 www oregonfuelinjection com 10
12. mine whether or not the terminal is making good contact or whether it has been damaged from prior improper connection multiple connections or lack of connection COMMON CODES EUGENE 4036 West 1 Ave Eugene OR 97402 541 485 1434 8 28 2015 www oregonfuelinjection com 8 OREGON FUEL INJECTION INC Note multiple codes can set for just one fault as if the other codes wanted to come to the party On an OBD2 system use the Tech 2 scan tool to determine which code set first and under what condition A DTC P0370 17 can trip a DTC P0251 18 a DTC P0251 can trip a P0335 19 and a DTC P0335 can trip a DTC P1216 35 or DTC P1217 36 DTC P0216 34 injection pump timing control circuit 1 Watch the stepper motor and make sure it retracts when activating TDC learn with a scan tool If the stepper is not operating properly this code will set 2 This code will set if injection pump timing has not been set correctly 3 It will also set sometimes if the crank sensor is faulty 4 If the stepper motor shaft was bumped hard during handling while the pump was off that can cause the stepper motor to bind and quit working DTC P0236 78 turbo boost performance 1 This code is usually caused by a bad wastegate controlsolenoid or low system vacuum 2 Check vacuum at the wastegate actuator connectionon the turbo It should be 15 at idle If it is not and vacuum at the inlet to the wastegate solenoid is at least 24 then t
13. olenoid inside the injection pump not a PMD EUGENE 4036 West 1 Ave Eugene OR 97402 541 485 1434 8 28 2015 www oregonfuelinjection com 2 OREGON FUEL INJECTION INC e Ifthe PMD is missing the heat transfer pad it can overheat and cause intermittent stalling e Ifthe PMD is not mounted to the a heat sink either the pump housing If the problem you are experiencing doesn t correspond with the problems noted above then follow the trouble shooting below to help pinpoint a possible bad PMD GM Bulletin 77 63 06A follow these instructions if PMD replacement guidelines do not apply 1 Check fuel system for air check at fuel return from pump supply pump pressure and fuel filter condition 2 Check the PCM and injection pump wiring harness for chaffing and or loose terminals at the PCM connector the 15 pin connector and the PMD connector See the WIRE HARNESS CONNECTIONS section for more information 3 Check all engine and vehicle harness grounds 4 Check for loss of ignition voltage on terminal D at the PMDconnection to the injection pump Refer to ENGINE CONTROLS IN THE 1998 SERVICE MANUAL FOR ALL MODEL YEARS 5 Verify that the condition is still present If the condition is no longer present the vehicleis repaired If the condition is still present and there are active DTC s set go to step 6 If the condition is still present and there are NO active DTC s set go to step7 6 For
14. tin noted below Also be aware that the PMD is powered by a quad driver circuit in the PCM This circuit also powers the EGR vent solenoid EGR control solenoid wastegate control solenoid and the 1 2 shift solenoid If any of these solenoids have an intermittent short the thermal protected quad driver circuit will trip and shut down all 4 circuits which can cause intermittent stalling then reset and run again Check for system voltage between the pink and black ground wires at the wire harness connection to the PMD and Fuel Control solenoid 4 wires it should be battery voltage Fix low voltage issues as well as any other problems such as no fuel supply pump pressure before replacing the PMD Replace the PMD if 1 If complaint of intermittent dies with no codes and you can t duplicate it remember that a bad noise suppression harness can cause intermittent stalling Intermittent dies with no closure errors closure errors are usually caused by the fuel controlsolenoid 2 Intermittent stalling and C Time varies as normal during acceleration and deceleration if C Time is stuck at 1 95ms or 2 25ms this usually means a bad fuel control solenoid 3 If you have amo start and C Time is 1 95ms 94 95 or 0 01ms 96 2000 replace the PMD 4 C Time is erratic at idle while idle rpm is stable Note e Normal C Time is between 1 5ms 1 9ms C Time readings that are too high but stable are usually a result of a bad fuel control s
15. ue to aeration in the fuel after all it is an optical sensor and it can t see through an aerated mix MISFIRE CODES Misfire codes are handled differently for different years Some misfire codes go by firing number order in other words a misfire code for 2 would be 8 cylinder because it is the 2 cylinder in firing order Check the service manual for the year you are working on Firing order is EUGENE 4036 West 1 Ave Eugene OR 97402 541 485 1434 8 28 2015 www oregonfuelinjection com 6 OREGON FUEL INJECTION INC Firing Order 1 8 7 2 6 5 4 3 INJECTORS The injectors on the 6 5L are usually only goodsfor about 100 000 miles They get a lot of carbon blown up inside of the nozzle tip This results in poor atomization and poor spray patterns ENCODER SENSOR If you have a no start condition disconnect the encoder optical sensor and crank the engine for 15 20 seconds Ifit starts then the problem is with the optical sensor The encoder sensor has 4o be able to see through the fuel inside the pump if there is any air in the fuel it can cause trouble codes to set Dirty fuel SVO no fuel supply pressure air in system or dyed fuel can all cause a problem with the encoder sensor reading the windows in the cam disk There are 8 windows in the low resolution circuit and 512 windows in the highresolution circuit In on minute at idle the high resolution circuit needs to read about 180 000 win
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