CK5
Register an account today to become a member! Once signed in, you'll be able to participate on this site by adding your own topics and posts, as well as connect with other members.

6.5 diesel, no start.

urbex

1/2 ton status
Joined
Jul 16, 2014
Posts
386
Reaction score
150
Location
Glendale, AZ
Truck is a recently acquired '96 K2500, 6.5 diesel. Fired right up in the mornings no problem. Drove it around my property a few times without issue, took it a few miles down the road to the gas station and back, no problems. Several hours later I run it down to a gas station 15 miles away, fill up the tank with diesel, go the grocery store a few miles away, spend an hour in the store, and come back to a truck that wouldn't start.

Cranked fine, but wouldn't fire. Sounded like it kinda sputtered a couple times, but nothing solid. Tried cycling the key several times to the point that the wait to start light would blink on and back off immediately, still wouldn't fire.

Noticed I didn't hear the lift pump running. Crawled under the truck, and found the fuel pump wiring from the pump to the connector soaked in diesel, and the plug itself was full of diesel when I pulled it apart. Shook the diesel out, plugged it back in, cycled the key, still no pump running. Tried putting truck in D, turned key to start, still didn't run lift pump (not sure if this applies to '96+ trucks or not, just something I found while googling while waiting for a tow truck to arrive after I killed the batteries trying to crank it).

At this point, I haven't had a chance to do any diagnosis past what little I did in the parking lot. PO relocated the PMD to the driver's side fender behind the battery, in front of the master cylinder, and it's on a big heat sink. I did find a document on no-start diagnosis that I'll go through as well. I'll try jumping the pump when I get home and verifying power to the pump, but I'm thinking that the wet wiring and plug is a pretty good indication that the pump needs to be replaced anyways?

Oh, and I've also been getting a P0231 - Low Voltage Fuel Pump Secondary Circuit, which apparently has something to do with the lift pump? Not exactly sure how the ECM detects that, or what specifically it's referring to...just been researching while I have a free minute here and there at work today.
 
Last edited:
That generation of truck the computer controls/powers the lift pump via the oil pressure sensor. There are kits to change it the the sensor activating a relay. Running an aftermarket lift pump is also a good idea.

Quadstar tuning and Leroydiesel both sell tons of stuff for the 6.5s. I recommend changing/upgrading the oilcooler lines if they haven't been done.
 
Well....came home from work today, and decided to try the simple stuff first - swap the fuel pump relay from one of my parts trucks, turned the key on, heard the fuel pump light up, and the engine fired right up with no hesitation.

Swapped the old relay back in, and same thing...maybe the relay contacts are loose?

Figured I already bought a replacement lift pump, might as well put it in, just in case. Went to loosen the tube nuts, and found the front line barely finger tight... well, that explains the diesel soaked wire and connector, lol.

Lift pump must have been replaced somewhat recently, as it's a Delphi pump. I put the new Precision pump in anyways, and I'll toss the Delphi in the spares box in the truck.

On to replacing the fuel filter now...
 
Ah loose connections, they'll drive you nuts. Glad it's looking like simple fix.
 
Top Bottom