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2004 GM Truck 2500HD 6.6 Duramax Cranks No Start

Jul 09, 2022
well good morning viewers today we have a

2004

chevrolet silverado 2500 hd it's a long bed extended cab with the 6.6 max dirty it's here it was towed for a crank no

start

condition apparently the story is the customer was using had it parked for a bit while a block plugged into the block heater apparently failed don't know where the wire is but it seems to work fine so let's take a look at some data parameters and take note of some of the inputs from the computer so let's go I

start

ed by hooking up a scanner to this thing well the first thing I noticed before we started booting this thing up is that it's not an OEM key and I'm not sure if you have security on this key so that might be the cause of the problem, so i'll put the key in the ignition and take note of a few lights on the dash before proceeding.
2004 gm truck 2500hd 6 6 duramax cranks no start
One light we want to focus on is the check engine light and the security light next to it. security light went out and check engine light is on looks like you have a heater heater issues with the doors cut off or something is ok let's take a look at some data ok so i haven't scanned this vehicle before , let's see this is an o4, it should I can't automatically identify it because of the aging of the vehicle I'm going to see, oh yes, it did and it has 143,000 kilometers which is not much 143,346. well, now this due to the age of the vehicle and this stupid snap scan tool doesn't allow a network scan so i'm going to go into the engine and check for codes engine auto codes menu display codes all powertrain codes i have a booster battery connected well it has a glow plug issue but that shouldn't stop it from firing a glow plug on cylinder number eight lets look at some data from engine one i'm going to create a custom data list here so here are the data parameters that i think are important for a start engine speed coolant temp air temp barometric pressure actual fuel temp fuel rail pressure and fuel rail depress on oh Did you run out of fuel, by the way?
2004 gm truck 2500hd 6 6 duramax cranks no start

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2004 gm truck 2500hd 6 6 duramax cranks no start...

No, it has just under three-fourths of the ignition voltage of the tank. the fuel rail pressure is in megapascals and it's 1.4 megapascals so let's look at this here and the

truck

is at 28.9 inches of mercury which sounds like a reasonable engine speed and where are the signs cam ok let's fire it up and see what happens we have a Engine rpm's not very fast but we don't have fuel pressure as you can see here the actual fuel rail pressure is 1.4 megapascals so I wonder if this thing has lost its prime. loosen with a quarter inch drive 13 mil loosen by a half couple turns then pump this plunger now no fuel coming out thats for sure now we have fuel let's go back and see if it will start now sometimes the check valves on these fail and cause them to leak priming we could also have a leak on the suction side of the fuel lines sometimes rusty fuel lines so I'm not pulling a custom data list but now I see minus 40 for the fuel temp sensor so that's not correct but that shouldn't cause it to not start let's see the fuel rail pressure where is the actual fuel rail pressure?
2004 gm truck 2500hd 6 6 duramax cranks no start
Engine speed is just below. Digitally I could have a stuck open pressure regulator, I'm assuming I'm not doing any high pressure fuel pressure. not at all desired why that zero is weird it wasn't zero before hmm we got some weird data parameters here now coolant temp is minus 40. intake air temps are minus 40. let's look at the engine rpm while it's cranking that's not ok let's cycle this turn the key off and back on see what happens i don't know if the scan tool is failing or if the ECM is failing there's engine rpm again now we have rpm that's weird let's look at the actual engine pressure fuel rail desired i have to power up a battery charger this thing and i wish ed fuel rail pressure no smoke from the tailpipe pit when for some reason we're not getting uh we're not getting fuel pressure try to bleed again ok i think firmly that it's a fuel issue because I've bled this like three times now and every time I open this bleeder as you can see there's more air I put in some propane from a propane torch, a little propane bottle right there on the air filter, it went off and ran for a few seconds but did nothing. fuel pressure so I'm going to remove this fuel line here this is the inlet line and this is the outlet line I think I'm going to see if I can take this fuel line out and put it in a clean container of diesel fuel so I decided that instead of removing the fuel line at the filter inlet, I would remove it here on the quick couplers.
2004 gm truck 2500hd 6 6 duramax cranks no start
I took the fuel supply and returned it and hooked them up to a two gallon can of diesel fuel. I realized I'm not sure what the return flow rate is like, but if I just supplied it in the inlet line most of the fuel would be back in the tank before I got it in the shop, I'm not sure, but i primed it now, let's see if it starts. no fuel pressure at all it's getting up there come on that confirms it we have a suction leak in the fuel system so im going to drive this carefully into the shop now where i can work on it more convenient. got this

truck

on the hoist the bottom line here is the suction line doesn't look bad no spots obviously rusted it's covered in oily residue now i see someone changed all the brake lines and i hope it wasn't a professional job done by a shop because they're just routed this way they're just rubbing the floor they're not sure I mean why wouldn't I buy the kit and put all the stainless steel lines in there and be done with it? dozen of them aren't that bad but that's secondary though, the lines don't look too bad unless they're engaged on top of the tank and I lent my boar scope to someone so I can't look up now that coupler you see there if you could disconnect it and put a piece of clear hose in the middle and reconnect the lines above and turn it on and watch for bubbles.
I would expect that once it is running it will keep running unless there is no fuel in the tank. Now I asked him if he had a problem with the fuel gauge and he said no it doesn't feel empty. I wonder if I film that with a thermal camera. If I can see the fuel level in the tank now that it's warming up in the shop. I'll try. If you look at the back of the tank, you can see that it is a huge tank. and i got the thermal camera here you can see the line as per the gauge i was at a little less than three quarters of a tank so you can see the black line indicating the fuel level the plastic is getting hot and the fuel it keeps it cold in there i think its more than half a tank anyway so i think there is fuel in the tank so i was wondering if the inlet or outlet on the fuel pump or no fuel pump fuel sender is rusty compromised considering the age of the truck that's very likely so I did a visual inspection as best I could from below with my old boar scope and can't see anything really wrong with the top of the pump or the fuel sender I should say so I blow the fuel from the line back into the tank with compressed air gently so that line should now be empty and I'm putting smoke in that line with my machine motorback smoke and we're going to pull it up now and see if we can see smoke coming out somewhere so the line contains about 12 inches of water which is about half a psi and there are no obvious leaks anywhere that I can see right now unfortunately this is positive line pressure and i could have a leak even on that seal there on that connection right there and it leaks under a vacuum so nothing obvious that's for sure and no sign of fuel when i blew the fuel back No sign of fuel looking here wow I'm going to try disconnecting this line here and see if I can put a piece of hose in the middle clean the hose and watch for bubbles but that's not easy and this fuel Ok let's go. try and disconnect that line so i dropped the frame cooler and was wondering why that line looked relatively clean so it was fixed you can see a sectional line was put in with a brass joint.
I have smoke under pressure. right now and i'm trying to release this fitting here and it won't release anyway i'm going to try to remove it and put a piece of clear hose in there and turn it on to see if there are any bubbles. the tank so i pulled that line out and it was uh it must have been a repair fixture or something someone put in there and if i put smoke pressure in the system now you can hear the fuel bubbling inside the tank but no leak here i can see I only push the line in partially so I'm going to go to the hardware store and get some clear line and a half inch copper tubing so I can make or reproduce this connection so there's a half inch piece of clear tubing on the line suction on that accessory.
I used a 1/2 inch piece of aluminum tubing from a scrap AC pipe in the correct dimension on the outside no need to clamp it no pressure on it actually there is suction so we're going to do the same on the top on the two lines on the engine ok i've bled this thing like four or five times and it keeps running out of fuel even when i'm trying to bleed it it just ran out of fuel again there's the line you can see that no fuel coming out the filter housing is nothing more than air bubbles coming from the tank The problem is I don't have a helper here to start this vehicle and look at the air bubbles underneath but I'm sure there are no leaks anywhere to along the line it has to be leaking pickup or pickup in th tank I hate dropping that fuel tank cause it's three quarters full oh well I'm going to get a helper I've tried san I've replayed this a half dozen times I'm getting fuel but it's not consistent I've taken the fuel tank out of the equation now and hooked up the fuel tank or gas can here and I still can't get it to bleed so I'm starting to believe there's a suction leak on that line.
I wonder if it is leaking where that junction was placed. aftermarket I'm thinking of just running a new line of course the line smoke test is inconclusive because it's very low pressure and this line is really under vacuum so I'm thinking of running a new line or cap the line at one end and pressure test to see if I can see a specific leak now that there is fuel in the line so I kept the line in the tank at the connection that goes to the short tube in the tank so which should be locked and sealed and if i put a vacuum pump on the line as you can see it doesn't hold vacuum however i can't see a leak anywhere.
I don't think it's these o-rings. I pulled out the coupler from below and checked it there. and the cooler down there has a hole in the pipe and yet it doesn't seem to be leaking you would think if i push it now it will leak fuel because there is fuel in the pipe so i am going to run a new line from here to the tank connector then see if we can prime it so it's tied along the frame connected to the elbow coming out of the tank after about 15 minutes of running you can see there are no air bubbles in the return line and we'll do a full road test.
It needs a real quick replacement for the number eight so we'll get to that later so we've just come back from about a 15km road test. trip this has low mileage considering the age of the vehicle if that odometer is correct and uh other than th The glow plug i ordered i think i'll see how it starts up tomorrow morning before i return it to the customer but i think this will solved, so thanks for looking.

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