1994 - 2002 GM OBS 6.5L V8 Diesel Engine Fuel Filter Manager & Fuel Hoses Replacement (Chevy & GMC)

Рет қаралды 17,078

Күн бұрын

In this video we will go over fuel system maintenance for the GM 6.5L V8 diesel engine focusing on replacing aging rubber fuel hoses and rebuilding, and replacing, the Stanadyne FFM (Fuel Filter Manager or just Fuel Manager) assembly. This fuel system maintenance is specific to the electronic fuel injection version of the 6.5L diesel engine, with the Stanadyne DS4 injection pump only.
The truck illustrated is a 1999 Chevrolet K1500 Suburban LT, but the procedure will be the same for any 1994 thru 2002 GM OBS C/K truck with the 6.5L diesel engine. Chevrolet, GMC, and Holden for Tahoe, Yukon, Silverado, Cheyenne, Sierra, Blazer, and Suburban across C1500, K1500, C2500, K2500, C3500, and K3500 weight ratings.
The eBay and Amazon search links below are paid links, for which I may be compensated and earn a commission, if you choose to buy the parts and tools shown in this video thru them (note several of the parts are discontinued by GM/Stanadyne):
Fuel Filter Manager (FFM) assembly GM 10226035 / Stanadyne FM100 top loading: ebay.us/GQYUSU or amzn.to/3Qcpfhs
Fuel Filter GM 10154635 / ACDelco TP1256 / Stanadyne 31712: ebay.us/yQZPSn
Fuel Filter Nut GM 12511963 / Stanadyne 28694: ebay.us/C5z1dl or amzn.to/3Q9RZHw
Fuel heater assembly GM 12511964 / Stanadyne 29241: ebay.us/wpZ4uR or amzn.to/3WDZ1a1
Fuel heater o-ring GM 12511962 / Stanadyne 28869: ebay.us/neSDyO or amzn.to/3IgaDeQ
Water in fuel sensor GM 12375515 / Stanadyne 29257: ebay.us/JKlvOE or amzn.to/3VFJFjY
Water in fuel sensor o-ring GM 12511959 / Stanadyne 27602: ebay.us/6xNbDn
Fuel Manager pre-filter screen Stanadyne 29244: ebay.us/PyelCy
Fuel hose 1/4" bulk line GM 9438257 rated GM 6165-M: ebay.us/ZbripQ
Fuel hose 1/4" bulk line GM 9439402 rated GM 6163-M: ebay.us/VofPRJ
Fuel hose 5/16" bulk line GM 9439550 rated GM 6165-M: ebay.us/YwYqkm
Fuel filter manager inlet 90 degree elbow 3/8" GM 10228324: ebay.us/XYpdZJ
Fuel injection pump inlet molded hose 1/4" GM 10229337: ebay.us/PzyxHl or amzn.to/3vxKDEe
Fuel line 1/4" - 5/16" worm clamp GM 25518880: ebay.us/zX4pgK or amzn.to/3Z3DgC1
Fuel hose plastic conduit wrap GM 8919355: ebay.us/yvKy03
Upper intake manifold crossover gasket GM 10137537: ebay.us/AXsxyo or amzn.to/3YYQWyh
Permatex 81158 black adhesive sealant: ebay.us/vJESu9 or amzn.to/3VDQ674
Fuel injector return hose GM 14066305: ebay.us/syjeCg or amzn.to/3WVlKho
Fuel injector return cap GM 14066301: ebay.us/qhBuOx
GM factory service manual: ebay.us/I3s5TZ
Stanadyne Service Bulletin 469: www.stanadyne.com/dealerporta...
And if I've saved you some $$ here, consider some coins for the coffee tip-jar! ko-fi.com/drshock
1994 1995 1996 1997 1998 1999 2000 2001 2002
Chapters:
0:00 - Project overview
0:20 - Removing the engine cover
0:27 - Locating and removing the injection pump return hose
1:36 - Removing the intake manifold crossover assembly
3:34 - Locating and removing the injection pump feed hose
4:29 - Locating and removing the fuel filter manager drain hoses
6:30 - Locating and removing the FFM
7:44 - FFM teardown and rebuild considerations
12:21 - Service manual technical information
14:18 - Parts explosion and part numbers
20:23 - Fuel heater assembly testing
25:06 - Water in fuel sensor testing
27:21 - FFM reassembly & installation
30:48 - Final reassembly
#drshock #obstruck #obstrucks
Disclaimer: DrShock, the alias for the human content creator for this KZfaq channel, is not responsible for any damages, injuries, losses, or liabilities associated with any repairs, upgrades, or maintenance performed on yours, or any other, vehicle whatsoever. No warranty, express or implied, is made as to the accuracy or completeness of any information provided within this channel. Viewing and using the “as-is" information of this channel is totally at your own risk. Always wear personal protection equipment and follow appropriate vehicle manufacturer service manual guidelines with original manufacturer parts only when performing any repairs, upgrades, or maintenance upon any vehicle.

Пікірлер: 62

@Yorktorq89 Ай бұрын

what an amazing video. I’m doing the job now 6/19/24 and this is coming in sooo nice. Thank you very much !!!

@Milkman3572000 16 күн бұрын

You have patience and skill. Bravo.

@andrewbeveridge3006 11 ай бұрын

Great video as usual... great info and to the point! Love it, keep it coming

@huicogopar Жыл бұрын

Thank you for sharing your wisdom with us,i don’t know if you’re an engineer but you sure are one of the 2 percent God bless

@DrShock Жыл бұрын

Thanks, my academic and professional background is in engineering.

@joestone2068 Жыл бұрын

Thank you for such a great video as always you were very informative. What procedure did you use to bleed out any air in that fuel system after changing the hoses and the fuel filter manager thanks in advance

@DrShock Жыл бұрын

Thanks. You vent the air out of the fuel filter manager the same as when you change the fuel filter, using the top vent valve present for that purpose. Residual air in the new fuel lines will be purged naturally by the fuel injection pump during the initial cranking sequence after the repair.

@joestone2068 Жыл бұрын

@@DrShock thank you I was wondering if that would do it. That hose that feeds the injection pump with the 90 on it did not go all the way back to the fuel filter manager or did you have to splice shit together? At the moment I have my intake off, because I must have a small leak somewhere because I can smell diesel fuel on the heart engine, but can’t seem to find where it’s coming from. So maybe I should change all my hoses too. Thank you so much you have been a lot of help. I love all your videos. You do an excellent job.

@DrShock Жыл бұрын

No splicing required with the original GM part numbers. It all fit back the same as when originally manufactured, correct lengths, bends and all.

@ronbenson4793 Жыл бұрын

Great video and explanation as usual I think I will do the same running a 1998 6.5 so I'm sure my hoses will also need replaced, and sensors tested.

@inktownfishing4505 11 ай бұрын

Thanks for this video very informative, just like all of your 6.5td video's.

@duanethieme4186 4 ай бұрын

Great info/video!

@rossconverse9067 3 ай бұрын

Thanks!

@andrewbeveridge3006 5 ай бұрын

Turbo power for the win ❤

@miguelsantanaguerrero5722 7 ай бұрын

Dr. Shock, great video as always! I have a question for you, I have 94 Chevrolet Silverado 3500 6.5L diesel truck which I am curently having problems with. I warmed the vehicle a day before using it (it had been off for a while) and it started good. The following day, when I turned it on, I noticed that it was a bit weak and when I tried to go up a small hill about 1/2 mile from my home, the truck stopped moving, started making a loud and strange noise from the engine, the vehicle started vibrating, and black smoke was coming out the exhaust. I turned it off and waited a while then turned it back on, but the vehicule still would not move. I got it towed to my house and tried to turn it on a couple days later. I noticed it was a bit low on disel, so I put diesel in, bled the truck and some air came out the system, but it still would not turn on. What do you believe the problem could be?

@eedom69 11 ай бұрын

Ok they are 15mm. I was wondering. That's what was closest but still a little loose with the socket but deep socket did feel a little tighter. I'll try tmrw. I was afraid to strip those. That kind of bolt I don't like. It reminded me of the transmission pan drain plug. I am still working on my glow plugs, lol I got 6 new ones, one that's waiting for a new 56 terminal in the mail and one that's still stuck! I tried extractors and no luck. It won't turn. Thought if I had the opposite of the reverse bit I could try tightening and then loosening back and forth but idk. It seems impossible. Can't drill anymore into it. Maybe it needs welding a nut to it or smthg from an expert. Anyways I have a leak in the valve covers and started taking it apart. Not sure if you have a video for that, but thanks for this again.

@giuseppecipolla447 6 ай бұрын

Thank you for the very useful video. For a few weeks I've had the following problem: on the first start-up attempt with a temperature of around 50f the engine starts but after a couple of seconds it mumbles and switches off, a touch of the accelerator does nothing. If I try to restart it immediately it won't turn back on. If I wait a couple of minutes when I turn it back on it starts up again like the first time, it grumbles a little but with a couple of touches of the accelerator it settles down and then works correctly. When hot it turns on regularly. I had thought that the line from the tank to the FFM empties during the idle period and then creates air immediately after switching on. What test could I do to verify the theory?

@stuartkreitman1545 10 ай бұрын

I am putting in a new FFM. Need reassurance which is which on the 2 steel hoses on the driver side: One is from the lift pump to FFM. The other is the fuel return network. One of them sticks out further than the other.

@DrShock 10 ай бұрын

Your FFM, if a genuine OEM unit, is going to be marked as to inlet and outlet on the aluminum casting no?

@Stukreit 10 ай бұрын

@@DrShock The delco FFM is well marked. I am referring to the hard lines coming up from below. One is the lift pump line, the other is return-to-tank

@DrShock 10 ай бұрын

If you mean which of those hard lines is which based solely on their resting position at the bellhousing, this can vary by vehicle model. It can also vary by how they are entrapped by the loop retainer(s) secured by the bellhousing bolts (some vehicles will have the inlet closer to the engine, others would have return closer). I would manually verify the inlet hard line by following it up from the lift pump rather than it's physical position at the bellhousing.

@jmacedo7 Жыл бұрын

Dr.Shock 👏👏👏 Muy buen tutorial video explicado con detalle 👌. Hay algo que quiero preguntarle, agradecería su respuesta, después de renovar las viejas mangueras y limpiar el la carcasa del filtro de combustible y hacer las pruebas a los accesorios, No le intereso Actualizar la linia de salida que va hacia la bomba de inyección de 5/16" a 3/8"? Se lo comento porque hay foros en la web hablando de la deficiente linia de suministro de combustible que la GM impuso, y los desgastes prematuros que puede provocar al DS4(IP) Y mas si remolcas o eres de conducción muy rápida, teniendo que hacer vacío la I.P. y calentándose por la falta de combustible constante en esos picos de demanda y que a la LP le cuesta trabajo entregar y mas por restricción de la linia 5/16" : hay un kit no muy caro o que uno puede tratar de hacer Llamado : FTB (“Feed That Beast!”) , Dr.Shock le puedo decir que talvez no fue la gran cosa, pero si me ayudo(talvez me falto actualizar la bomba Elevadora de combustible, pero ya no tenia presupuesto) cuento con un medidor de presión de combustible de paso, 0-15psi instalado en el marco lateral del parabrisas y le puedo decir que ante con la manguera 5/16" a medio acelerador el medidor caía 0 psi y ahora actualizada a 3/8" la caída a 0psi es 3/4 acelerador presionado aproximadamente, (no crea que ando midiendo el recorrido del acelerador😁) pero de que me soporta un poco mas, me soporta y para conducción citadina, económica y alargando su vida útil. estoy conforme; Agradezco su humilde opinión .

@DrShock Жыл бұрын

Gracias. En este video muestro el reemplazo de todas las líneas de combustible originales con piezas OEM originales de GM. No soy fanático de usar piezas o accesorios del mercado de accesorios. En cambio, prefiero mantener los vehículos exactamente como los diseñaron los ingenieros del OEM. Los ingenieros de GM y Standadyne eligieron la línea de combustible de tamaño estándar para cumplir con las especificaciones de rendimiento y economía de combustible. Sin embargo, ciertamente no dañará nada, aparte de quizás la economía de combustible, para hacer el mod FTB. Simplemente no es algo que personalmente le haría a mi vehículo o al de otra persona. La única modificación al motor de 6.5 L de la que soy fanático es actualizar el PMD negro suministrado por GM al último modelo de diseño Standadyne _gray_ one. Y luego montarlo de forma remota en el área de la fosa nasal del parachoques delantero. Esta es un área que los ingenieros definitivamente pasaron por alto.

@SCVM__ Күн бұрын

I had a diesel leak, the fuel heater wires shorted out, Mechanic said I was very lucky My Truck didn't burn.

@justing6594 Жыл бұрын

Great video! Very detailed. I have a question? Do you know what the bracket is called that sits on top off the fuel filter manager? It has 3 plugs on it?

@DrShock Жыл бұрын

I believe you are describing a wiring harness mounting bracket. It shares the mounting bolts with the FFM, and holds several wiring harness connectors at the back via press in plastic tree connectors.

@justing6594 Жыл бұрын

@@DrShock yes sir that sounds like it. I had an electrical fire. So now I have to find out where thouse wires go. Long story short I could not get the bracket to go back on after replacing the ffm so I left it off. And apparently a wire melted. Thanks so much for replying! And have a fantastic day!

@chupacabra1765 6 ай бұрын

Very detailed vid. Question? is it possible to test fuel pressure from the lift pump at the T valve? and what's the cost on the fuel management assembly?

@DrShock 6 ай бұрын

You could test it there but you would need to pull the hose off the T for an accurate reading. Given the age, be prepared for the hose to _disintegrate_ upon removal. ;-)

@tarquineous 2 ай бұрын

I was waiting to see the replacement plastic that goes over the center tube inside the manager housing. Is it available without going to a new assembly ?

@DrShock 2 ай бұрын

I'm not aware of that part ever being separately serviced by Stanadyne. Unless you are referring to the white nylon screen at the bottom there? That part is serviced, and is listed in the video description.

@tarquineous 2 ай бұрын

@@DrShock I will certainly check it next filter change.

@glennlockwood7608 10 ай бұрын

at what temperature does the heater shut off; i.e. what temperature fuel does it supply to the injector pump?

@DrShock 10 ай бұрын

Not documented by GM or Stanadyne in their service manuals.

@jrruiz4407 11 ай бұрын

Question man I got a 96 6.5 if engine it’s cold it start right and runs like a champ but ones u turn it off it won’t turn on again just cranks could this be causing it ? No engine light

@DrShock 11 ай бұрын

Hard to start when hot unfortunately has a list of possible cause categories that have to be individually diagnosed. Fuel is certainly one of the categories. You can verify alot of the fuel delivery system operation just by checking fuel flow/pressure on the outlet side of the fuel filter manager at the brass t-fitting that is used to purge water out of the housing. Getting a passing test result at the t-fitting crosses off the fuel filler cap, fuel tank inlet sock, the lift pump, the fuel filter, and the fuel lines into the injection pump.

@jrruiz4407 11 ай бұрын

@@DrShock thanks i appreciate that

@medinafrancisco12 7 ай бұрын

On the cutaway or van versions, The filter is underneath correct?

@DrShock 7 ай бұрын

I don't know about P-vans, but on G-vans like the Chevrolet Express it would be on the drivers side frame rail. The replacement procedure and filter housing design is different than the C/K truck version I show in this video though.

@medinafrancisco12 7 ай бұрын

@@DrShock Thanks

@partyboy1ize 8 ай бұрын

Can the ffm be relocated for better access in the future?

@partyboy1ize 8 ай бұрын

Or is there a after market ffm?

@DrShock 8 ай бұрын

I'm not aware of a direct aftermarket version of this particular part, but I only work with genuine OEM parts myself.

@ronstermonster47 25 күн бұрын

What about bleeding off the filter?

@DrShock 25 күн бұрын

That's pretty routine maintenance stuff, covered here kzfaq.info/get/bejne/lZZ_a9CrtcudoHk.html

@andrewbeveridge3006 11 ай бұрын

Could you use regular lines, without bends vs the pre bent lines?

@DrShock 11 ай бұрын

You could use regular fuel hose, but you'll have to leave extra length and find a way to secure it to prevent kinking. The reason it's molded into an angle is to prevent the kinking in those bend areas.

@glennlockwood7608 10 ай бұрын

What were the symptoms exhibited prompting repair?

@DrShock 10 ай бұрын

Age (rubber hoses dry out and crack and sediment accumulates in the FFM after a few decades).

@glennlockwood7608 9 ай бұрын

I have hard start despite good cranking speed and good glow plugs; modest blowby. Really hard start below 60F. Once it has been running it starts fine. But after it sits several hours it has to crank a lot to start. I'll follow up after I replace these components for the benefit of your viewers. I've replaced the tank due to a leak and all the hard lines up to the firewall. The lift pump was found to be inoperable with these repairs, traced back to a bad ground near the tank in the frame rail.

@DrShock 9 ай бұрын

FWIW the FFM heater isn't going to come into play until you're getting below 20 degrees so that's not going to be related to what you're experiencing. If the fuel lines are not aged out (cracking / brittle) there's no need to replace them either. I would connect a fuel pressure gauge and clear fuel line hose to the output of the FFM going into the injection pump. If you have the GM service manual specified psi (it's very low on these diesels), and no air coming into the injection pump, then it's not a fuel starvation problem either. I would determine whether a failing PMD is a contributor to this hard starting behavior before throwing parts at the fuel delivery system. This TSB can be helpful - oemys-performance.com/media/pmd%20sb-77-63-06a.pdf

@mobilemechanic2304 Жыл бұрын

do you have or know where I can get the manual repair?

@DrShock Жыл бұрын

They have been out of print for many years, but there's a search link in the video description you could try.

@paveltolz6601 7 ай бұрын

I got lucky at a dealership in a smaller city that still had a printed set on the shelves. Case of Beer and $40 for five 1997 manuals.

@markstack2309 18 күн бұрын

Why not up grade with a fuel dog or similar. 2 filters and adjustable fuel psi with heater just wondering

@DrShock 18 күн бұрын

First, well it's not my truck, but rather someones I've handled all the service for over many years. Second, I've got many decades in GM factory restoration work. Numbers matching show cars and trucks where date codes, stamping codes, and OEM originality are paramount. So even when doing side repair jobs for myself or others like on this old diesel truck - I prefer keeping everything OG.

@markstack2309 15 күн бұрын

@DrShock 6.5 for years was the most misunderstood engine. I used to live in nw Pennsylvania and was working on them way back in 94. I still have my 93 4 door dually 2 wd. Starting to build another engine. I love it it stands out it might not make 1200 hp but enough to keep me smiling. Stay safe