That switch would work good to use for a mojave heater behind the center console. Wonder how hard it would be to add defrost. Well nice truck man maybe mine will be that nice one day.
CK5
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91 Suburban V2500 - Tow/Weekend Rig - Build Thread
- Thread starter dhcomp
- Start date
Thanks!
No real need for rear heat, my 3rd seat is rarely in. Plus, even if its cold....i only sit in the front
Wow, long overdue for an update.
Over the last 6+ months, I've been on a road a lot of weekends.
Keeping my eye out for the right axle swap to go to 4.10's, but haven't been too serious about it.
Around June, I starting having this hesitation/surging problem, where it would bog, surge, then slam into gear rapidly.
The issue was intermittent, worse at sea level, and would often go whole road trips without showing up. As time passed, it got more and more frequent.
Not going to go through the mind set of each repair, but over the last few months, I replaced:
IAC
O2
TPS
MAP
EGR Solenoid
Coil
Distributor
Ign Module (this clearly failed, unrelated)
And nothing helped the cause. Computer wasn't storing any codes, except an o2 sensor code. When it would surge, it would flash the Check Engine light briefly, but wouldn't store a code. Its worth noting that after a cold start, it would run fine for 2-5 min, then start surging, in Park.
After a while, it worsened to the point that the truck was not driveable.
At this point, I tore apart the TBI unit, and fully rebuilt it, including fuel pressure regulator diaphragm. No issues found, no improvement.
Then one day, after shutting it off, i heard the following noise from the fuel pump.
It primes normally, starts, runs, shuts off, runs, then starts clanking really bad.
So, i ordered the fuel pressure tester adapter, and checked pressure. 10.75 approximate, and no drop when hesitating. Had always been nervous of the Fuel Pump age, and after the wierd noises, I dropped the tank and swapped it out. Factory Delphi pump. Just replaced the pump itself, as I could not find the whole unit anywhere local, and my sending unit was in fine shape.
For anyone about to do this, Get a cheap trans jack from harbor Freight. I think its $60. Screwed some 2x4's across it, and had a super easy way to drop the tank. Have no idea how else you guys get this done. It had about 1/2 tank of fuel in it.
For all you rust belt guys....
After pump replacement, it ran fine for a couple min...then started stumbling again.
At this point, i had replaced ALL the sensors, check for vac leaks, and had no other ideas. A Reman AC DELCO ECM is about $150, and i figured the first hour of labor if i took it to a shop wouldn't be much less, so I ordered up a new ECM.
And GUESS WHAT?! It runs fine! I've put close to 500 miles on it since, and NO ISSUES at all!
Other than age, my only other idea as to why it failed is that my windshield leaks a little on that side. Anyone know if an insurance windshield replacement will put a new seal on for me? I can get it covered under insurance, as its got enough rock chips in it.
Anyways, REALLY glad to have this beast back on the road! Was about to pull the trigger on a 94 K2500 Suburban as a "temp" truck until i got this fixed, glad now that I stuck it out.
Over the last 6+ months, I've been on a road a lot of weekends.
Keeping my eye out for the right axle swap to go to 4.10's, but haven't been too serious about it.
Around June, I starting having this hesitation/surging problem, where it would bog, surge, then slam into gear rapidly.
The issue was intermittent, worse at sea level, and would often go whole road trips without showing up. As time passed, it got more and more frequent.
Not going to go through the mind set of each repair, but over the last few months, I replaced:
IAC
O2
TPS
MAP
EGR Solenoid
Coil
Distributor
Ign Module (this clearly failed, unrelated)
And nothing helped the cause. Computer wasn't storing any codes, except an o2 sensor code. When it would surge, it would flash the Check Engine light briefly, but wouldn't store a code. Its worth noting that after a cold start, it would run fine for 2-5 min, then start surging, in Park.
After a while, it worsened to the point that the truck was not driveable.
At this point, I tore apart the TBI unit, and fully rebuilt it, including fuel pressure regulator diaphragm. No issues found, no improvement.
Then one day, after shutting it off, i heard the following noise from the fuel pump.
It primes normally, starts, runs, shuts off, runs, then starts clanking really bad.
So, i ordered the fuel pressure tester adapter, and checked pressure. 10.75 approximate, and no drop when hesitating. Had always been nervous of the Fuel Pump age, and after the wierd noises, I dropped the tank and swapped it out. Factory Delphi pump. Just replaced the pump itself, as I could not find the whole unit anywhere local, and my sending unit was in fine shape.
For anyone about to do this, Get a cheap trans jack from harbor Freight. I think its $60. Screwed some 2x4's across it, and had a super easy way to drop the tank. Have no idea how else you guys get this done. It had about 1/2 tank of fuel in it.
For all you rust belt guys....
After pump replacement, it ran fine for a couple min...then started stumbling again.
At this point, i had replaced ALL the sensors, check for vac leaks, and had no other ideas. A Reman AC DELCO ECM is about $150, and i figured the first hour of labor if i took it to a shop wouldn't be much less, so I ordered up a new ECM.
And GUESS WHAT?! It runs fine! I've put close to 500 miles on it since, and NO ISSUES at all!
Other than age, my only other idea as to why it failed is that my windshield leaks a little on that side. Anyone know if an insurance windshield replacement will put a new seal on for me? I can get it covered under insurance, as its got enough rock chips in it.
Anyways, REALLY glad to have this beast back on the road! Was about to pull the trigger on a 94 K2500 Suburban as a "temp" truck until i got this fixed, glad now that I stuck it out.
Last edited by a moderator:
On a frustrated day when I couldn't' figure out the hesitation issue, I finally rattle canned the roof. Laughed when reading one of my first posts on this truck, as I've had it close to 3 years now, and finally getting around to this.
Overall, I'll never rattle can a large item again. I didn't do very good prep, primed, and painted. Its all white....but we'll see how long it lasts. Truthfully, once I get axles/gears figured out, It will get a full professional paint job.
Overall, I'll never rattle can a large item again. I didn't do very good prep, primed, and painted. Its all white....but we'll see how long it lasts. Truthfully, once I get axles/gears figured out, It will get a full professional paint job.
After it was back on the reward, I replaced the Crossfire Marine Speakers i blew in the rear side panels. Killed the woofer in one, blew surround clean off the frame on the other 
Guess hours and hours of loud play time at 100w a channel will do that!
Replaced with some Infinity Kappa 6x9's.
Play cleaner than the Crossfires, but not nearly as much lows.
Guess hours and hours of loud play time at 100w a channel will do that!
Replaced with some Infinity Kappa 6x9's.
Play cleaner than the Crossfires, but not nearly as much lows.
Catching up on some lost updates, Took it up to Bear Valley on Labor Day.
We took 6 or 7 rigs, full of people, up to the top of Mt Reba. Easy trail, some steep washouts, but overall, the farthest off road i'd taken this beast.
My roommate brought his 69 FJ, which he hadn't really wheeled yet. Did well overall, but rather than mod it too much, it sounds like its getting replaced by one farther along in its build....
Before the end of the trip, we ran a narrower trail the burb wouldn't fit down with the FJ, and a new 4 door Jeep on 35's. Truthfully, I had never driven a manual trans truck in 4 lo, and ended up driving the Jeep for 1/2 the trail once the owner got tired. Had a blast. Would never consider an auto for a trail truck now.
Had a blast. Anyways, on to the pics...
It was a big Labor Day trip, and for some reason, this was Neon day. We looked ridiculous on the trail....
We took 6 or 7 rigs, full of people, up to the top of Mt Reba. Easy trail, some steep washouts, but overall, the farthest off road i'd taken this beast.
My roommate brought his 69 FJ, which he hadn't really wheeled yet. Did well overall, but rather than mod it too much, it sounds like its getting replaced by one farther along in its build....
Before the end of the trip, we ran a narrower trail the burb wouldn't fit down with the FJ, and a new 4 door Jeep on 35's. Truthfully, I had never driven a manual trans truck in 4 lo, and ended up driving the Jeep for 1/2 the trail once the owner got tired. Had a blast. Would never consider an auto for a trail truck now.
Had a blast. Anyways, on to the pics...
It was a big Labor Day trip, and for some reason, this was Neon day. We looked ridiculous on the trail....
Ok, now on to the fun stuff......
Other than troubleshooting a temp gauge problem, its time for some upgrades.
On the hunt for a 4.10 front and matching FF rear. REALLY trying to avoid moving perches, so looking for a 3/4 ton version.
As much as i've been talking and dreaming about an LS swap, Its a ways down the road. Wanting to control my 4l80e, as well as retain AC adds a lot of cost to the swap.
So....since I'm hoping to be in a lot better shape with 4.10's, i decided i should put a little money into this motor. I had been eyeing the CFM tech stuff, and after some more reading on this site, decided to pull the trigger.
Bought the full CFM-Tech packages of TBI mods, including:
Injector Pod Spacer
TBI Body Spacer -
Salad Bowl Power Charger
Adjustable Fuel Pressure Regulator
Fuel Pressure gauge and adapter
http://marine-performance-parts.com/gmtbiperformance.aspx
Biggest concern is getting the fuel pressure gauge adapter onto the hard line, and properly threaded back into the TBI.
Stoked to get everything next week and see what improvements it makes!
Other than troubleshooting a temp gauge problem, its time for some upgrades.
On the hunt for a 4.10 front and matching FF rear. REALLY trying to avoid moving perches, so looking for a 3/4 ton version.
As much as i've been talking and dreaming about an LS swap, Its a ways down the road. Wanting to control my 4l80e, as well as retain AC adds a lot of cost to the swap.
So....since I'm hoping to be in a lot better shape with 4.10's, i decided i should put a little money into this motor. I had been eyeing the CFM tech stuff, and after some more reading on this site, decided to pull the trigger.
Bought the full CFM-Tech packages of TBI mods, including:
Injector Pod Spacer
TBI Body Spacer -
Salad Bowl Power Charger
Adjustable Fuel Pressure Regulator
Fuel Pressure gauge and adapter
http://marine-performance-parts.com/gmtbiperformance.aspx
Biggest concern is getting the fuel pressure gauge adapter onto the hard line, and properly threaded back into the TBI.
Stoked to get everything next week and see what improvements it makes!
damn! good to see an update here man! thats funny about your roof, i dont think i'll be rattle canning my entire truck now, lol!
I don't have the TBI spacer but do have the pressure gauge adapter. It just screws into the pod and then the lines screw into it as normal. I'm sure you've read that you need to mess with (bend) your hard lines to get them in with the spaces.
Yep, bending the hard lines is the part i am nervous about. But, with the spacer, the added height might make up for the increased length. I may be trying to extend the return line instead of push the supply line back farther.
We'll see how it goes....
Ok, CFM tech stuff arrived.
Overall, no complaints about products. Surprised they don't make some sort of "kit" that comes with all their performance parts, with one set of instructions, but no big deal.
I installed:
Injector Pod Spacer
Adjustable Fuel Regulator
TBI spacer
Power Charger (Salad Bowl)
Gauge Adapter
Fuel Pressure Gauge
After having just rebuilt my TBI, the install was cake. Would defintely take longer if you have to clean/rebuild the TBI as you go.
Getting the lines to hook back up was a little tricky, but not impossible. Thanks to someone on here posting about a new rattle, i was able to figure out that my lines were rattling on the firewall after install. Need to bend them to clear.
On the first few miles, there is some improvment in performance. I'll let you know once I get some more miles, and drive some hills what my overall impression is.
Currently, Fuel pressure is set at 13PSI at idle.
Onto the photos:
Before:
Injector pod spacer vs original gasket
Spacer:
Gauge adapter vs. original adapter
Adjustable Regulator Parts:
Stock regulator:
Wondering why there was oil all over this? Malfunctioning PVC?
Regulator disassembled, showing diaphragm.
Stock regulator body:
Adj Regulator Body:
Adj Regulator Installed. Had to bend the vac port down a little to clear the knob.
Gauge Fittings:
Gauge oriented to Clear new air cleaner assembly
TBI Spacer Installed:
Gauge location, installed
Air cleaner before mod:
Overall, no complaints about products. Surprised they don't make some sort of "kit" that comes with all their performance parts, with one set of instructions, but no big deal.
I installed:
Injector Pod Spacer
Adjustable Fuel Regulator
TBI spacer
Power Charger (Salad Bowl)
Gauge Adapter
Fuel Pressure Gauge
After having just rebuilt my TBI, the install was cake. Would defintely take longer if you have to clean/rebuild the TBI as you go.
Getting the lines to hook back up was a little tricky, but not impossible. Thanks to someone on here posting about a new rattle, i was able to figure out that my lines were rattling on the firewall after install. Need to bend them to clear.
On the first few miles, there is some improvment in performance. I'll let you know once I get some more miles, and drive some hills what my overall impression is.
Currently, Fuel pressure is set at 13PSI at idle.
Onto the photos:
Before:
Injector pod spacer vs original gasket
Spacer:
Gauge adapter vs. original adapter
Adjustable Regulator Parts:
Stock regulator:
Wondering why there was oil all over this? Malfunctioning PVC?
Regulator disassembled, showing diaphragm.
Stock regulator body:
Adj Regulator Body:
Adj Regulator Installed. Had to bend the vac port down a little to clear the knob.
Gauge Fittings:
Gauge oriented to Clear new air cleaner assembly
TBI Spacer Installed:
Gauge location, installed
Air cleaner before mod:
Air cleaner cut out:
looks awesome. I didnt do my pod spacer cause I thought it needed gaskets
Way to read the instructions. It definitely says "this spacer replaces the gasket"
The gauge adapter instructions also say "There are 2 ports on this adapter. you MUST plug both before running the vehicle, or you will have a massive fuel leak "
Not even a sticker on it. I know how to do it now though
Darren, what kind of results did you get from the TBI mods?
Looks great and thanks for the photos. I just picked up a TBI rebuild kit yesterday and plan to install this weekend. I like the fuel pressure idea. Where did you get the extended assembly and gauge? I noticed both the original and new one have the flared end on the bottom. Does this make it harder to find?
Finally, did the fuel line bend back OK with the longer gauge assembly?
Finally, did the fuel line bend back OK with the longer gauge assembly?
Have a total of probably 5 miles on it since install. And it says it has to let the TBI computer relearn some of its programming.
So far, there is some improvement, but we'll see how it does after some miles.
Everything came from
http://marine-performance-parts.com/gmtbiperformance.aspx
They have the gauge adapter and gauge - not a simple part to find elsewhere. Its a custom part for this application.
Fuel line is challenging even w/o mods. When I rebuilt my tbi, i started to cross thread one of the lines, and had to clean it up to get it to thread properly. This time, lubing the threads helped me make sure it was started by hand far enough. Bending the lines was a little tricky, especially with the TBI spacer underneath. I hooked up the lines before installing the TBI. Once the lines were hooked up, i lifted the hole unit and slid the spacer underneath.
Happy to answer more questions on it if needed.
TBI rebuilt isn't bad, get a kit, and a bunch of carb cleaner to clean the unit before reassembly. You will need about 3 different sizes of torx screwdrivers - buy a cheap set. You will hate yourself if you are using bit adapters rather than a set of cheap torx screwdrivers.
At one time one of the spacer companies made short "fuel line extenders" to work with their spacers. TD Performance or TD, Inc or something. I had their 1" spacer on my '92's 350.
