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Re: GM service bulletin to fix air leak


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Posted by jdemaris on August 24, 2010 at 05:44:28 from (67.142.130.16):

In Reply to: Re: Questions about 6.2 GM diesel in C20 van posted by Roy Suomi on August 23, 2010 at 15:18:36:

Something doesn't sound right. Your filter is on the pressure side of the fuel pump, not the suction side. If it had a leak, you ought to see some fuel dripping. Also, if the fuel drained back because of a small leak there, the fuel from the filter would still be air-free. Just the injection pump would get a bit air-bound. That usually results in starting problems after being shut-down for a day. Engine starts hard, but does start and runs fine once it runs a bit.

There were several Chevy and US military service bulletins about the problem. Ford-IH 6.9s had similar issues caused by a Schrader valve leaking air.

The fix was to install an updated fuel pump, along with an updated regulator/check valve on top of the injection pump. Both had enhanced check-valves to prevent overnight fuel drain-back.

Here's a copy of the bulletin:

Chevrolet bulletin # 89-329-6
Subject: 6.2L Diesel Hard starting cold
Issue date: 9-20-91

All trucks with 6.2 diesel 1982-1989 except 88/89 CK trucks with electric fuel pumps.

Even if the glow system is working properly, some 1982-89 General Motors trucks
equipped with 6.2L diesel engines may still experience cold, hard starts. GM says air leaks
in either the suction or return side of the fuel system are the source of the problem. After
the engine is shut down, air leaks can result in loss of injector pump fuel prime.

If the air leaks are on the suction side of the fuel system, GM recommends installing a new
mechanical fuel pump GM P/N 25116503 and AC Delco P/N 43254. The new pump features a new ventless check valve to prevent drainback.

If the air leaks are on the return side, a new HPCA (Housing Pressure Cold Advance)
regulator valve (P/N 10149645) must be installed. This new valve and seal configuration
superceded the old ball check regulator valve....


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