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Help me get my 6.2 running

Can you describe said bracket so I can check? Thanks
In regards to the starter clicking... What do you think? Replace it? I want to get a new one tonight
 
Looks like I missed out on the fun!

The can with wires and 2 hoses is cruise control. It's not related to operating the engine, but if you follow the linkage on the bottom side you will find the IP. It will have the red/pink and green wires described below, as well as steel lines running to the cylinders and fuel input/overflow lines.

The glow plug relay that you have is not original (hence the missing spade lugs for that connector in your had). The glow plug controller on these trucks is a common failure point, and many folks opted to install a manual switch instead of repairing the controller. You may well have a controller on the other end of that disconnected 2-wire connector. Or you can keep using your switch.

These engines are quite cranky without glow plugs. Test each of yours with an ohmmeter (while disconnected from the wiring harness). Several types of plugs have been available for this engine, and some of the newer types are much nicer than the original AC 9G plugs that came with the engine. If your plugs are good you will have a low resistance value. AC 60G plugs run 0.7 Ohms. Whatever random plugs I have in my K10 are reading 2.5 Ohms. Burned-out plugs will register infinite (no connection). Lower resistance values mean more heat will be generated, which is a good thing. But Ohm's law tells us that a 0.7 Ohm plug @ 12 volts is drawing 17 amps. If the system didn't have physical limitations, 8 plugs would be drawing 137 amps. This is a huge draw, and it typically happens while you are trying to spin a starter motor (which is a bigger yet draw). This is why 6.2 trucks have dual batteries. You don't need both of them, but the starting process goes more smoothly if you can deliver more power.

Old plugs were rated for just a couple seconds at a time (and they burn out easily), and this shows up in the controller logic. Bosch Duraterm plugs are rated for continuous duty for hours at a time. So if you have new plugs the original controller will still be running them 2 (ish) seconds at a time, even though they can be run much more aggressively. This is one reason why I have kept the manual switch in my trucks. I can start much more quickly than I could with the old controller logic. :)

The starter motor should have a bracket at the front end attaching it to the block. Several issues can arise if this is missing, including shorter starter life and breaking the mounting holes off of the block. :doah: So it's worth replacing if it is missing. I have come across 3 trucks (so far) that were missing brackets, so I bought one new from the dealership and used it as a pattern to make several more out of a piece of bed frame. They're nothing fancy, but I may have one if you are missing yours.

Also, this engine originally came with a direct-drive starter motor (AC MT-27). Later on GM replaced this with a gear-driven starter motor (AC MT-28). The MT-28 cranks noticeably faster than the older direct-drive style. When I bought mine I brought in the old style and was handed the new style along with a sheet telling me how they are interchangeable. But, the newer one uses a shorter mounting bracket than the old one.


These engines have a few quirks, but overall, they are quite simple and very reliable. Once you have good glow plugs and no air in the lines, the engines are very easy to keep running. 12V at the IP (pink wire) is all that's required to start them. No electronics or complicated controllers to worry about. It's like having the simplicity of a carburetor with the dependability of fuel injection.


Lemme know what other questions you have. There are enough 6.2 guys on this site that we should be able to answer all your questions.
 
You have any more pics of what this truck looks like? More specs? If you are lucky enough to have a stick shift I would just tow it down the road and let that get the air-pumping done for you. Much easier to start with a tow than with a weak battery.
 
Which starter do you have? Is it a BIG starter (direct drive) or smaller, like what you'd see on a small block (gear reduction). Depends on which starter to which bracket you'll need. You can still get the GR starter brackets at the dealer...not sure about the DD ones. But if you're in a pinch, some angle iron can be made to work.

Be cautious with the starter if you have to replace it. if its the DD one, its pretty heavy and can leave a good bump on your noggin if you're not paying attention.

Also, I'd check the bolts first...as CUCVNUT said, the bolts have a tendency to break. Not good...so check it out. You'll want to make sure they're not broken...which can lead to that sound that you're hearing and the gear not fully engaging the teeth.
 
i do have more pics of the truck, or you can ask me for specific pics and I'll post them. It will be tomorrow when I have a chance to get on the computer cause for some reason my phone will not let me link pics to here. It is an auto (700r4). I wish it was the 465. The starter is the newer style gear reduction, the old one appears to be as well. And herkdriver not trying to act smart (you probably know diesels better than me) but just telling you that you had it backwards. The BIG starter is the gear reduction one and the little one is the direct drive. At least that's what the part numbers and pics on my new starter operating manual tell me. Can you guys tell me a foolproof way to get the glow plugs to work, regardless of whether that relay is bad or not? Is there a way? I need to know that my glow plugs are working before I spend all day cranking this thing haha. I'm gonna put the new starter in tomorrow and keep trying... Wish me luck, say a prayer for the ole jimmy. I'll let yall know how it goes. Thanks for all yalls help so far.
 
You can just jump the two largest studs on the glow plug relay with a jumper cable for 10 seconds or so,to activate the glow plugs,if the switch or relay has issues,so you can get it started.

The direct drive starter is twice as heavy as the gear reduction style,and the motor itself is larger than the one on the gear reduction one..the solenoid on the direct drive one is the same as an older gas V8 uses,the gear reduction solenoid is much shorter..
I've had both types of starters in my truck..bench pressing that direct drive ingot into place and holding it there while you get a bolt started is quite a challenge..

I had mine in and out 4 times one day,when the solenoid died ,I fixed the solenoid,then it refused to crank again--had to drop it again and repair the purple wire that makes it crank...then when I went to hook the battery cable up,the engine started cranking!..dropped it again,to reposition the battery cable--it was touching the stud on the solenoid for the purple wire..

Then after I got it back in and went for a ride,I had to try cranking it several times,before the starter would do more than just go "clunk" and not spin it over...thats when I hit the boneyard and scored a fairly new gear reduction one,which luckily still had that front bracket brace on it!..
 
Well I thought I had the gear reduction one which I thought was the bigass one. That's what the pictures on the new starter book said... Idk. I just want it to work. I'll let yall know how it goes tomorrow.
 
Well I went home at lunch and put the new starter in... It works! It cranks over and sounds normal, only had one battery in it when I tried cranking so it was spinning slower than it should. I did the jumper wire thing between the two big lugs, it sparked so I geuss it was working. I think I need to bleed the fuel system some more. Gonna do that when get home around 3. I'll post back then. Anybody got any suggestions?
 
It'll be best to have both batteries fully charged...you may have to boost them again before you get it to start..remember to let the starter cool off awhile between attempts,if you need to crank it longer than 30 seconds....

If it takes some cranking to finish bleeding the air out, it'll also help get oil pressure built up before it fires,which isn't a bad thing for an engine that has sat idle a long time..

I'm betting after you activate the glow plugs and get it spinning over fast enough, it'll run..dont race it once it starts--give things a chance to get oiled--I've seen once good engines that sat too long that were revved right up,have a valve hang open and hit the piston,you dont want that..

If you haven't changed the oil already I'd make sure it doesn't look milky or sludgy,it might have a lot of condensation from sitting in the oil...if it looks the usual coal black then you can probably run it till it gets up to normal temp and drain it and change it and the filter..

Good luck,let us know how you make out with it..
 
To save battery power, dont bother trying the glow plugs, untill you see smoke at the tailpipes. Once it starts blowing white smoke while cranking, stop and give it plugs, then crank again.
 
I'm hoping your right, I really want to hear it run! Quick question, does pumping the go pedal do anything to help a diesel crank up like it does a gasser?
 
You have to have good glow plugs to get it running. You can disconnect the wire and measure the resistance of each one to the block. They need to be mostly the same. An open circuit gives you a dead cylinder on cranking, but a shorted glow plug can give you 7 or 8 dead ones. Most of the current goes through the shorted one and the good glow plugs don't get as hot as they should.
 
Need help ASAP! While I have my buddies here lending me batteries... Here's where we are at, truck cranks over good and blows black smoke out the pipes but just will not catch, glow plugs are working.
 
Well guys, here's where I'm at, it wouldn't start, so taking advice from my neighbor who knows what he's doing (used to have a 72 k5) he says pull the injectors and clean them, so that's what I'm gonna do I geuss. Any tips on getting the hard to get at injectors out? Tips on the cleaning process, anything at all I should no?
 
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