1994 - 2002 GM OBS Trucks 6.5L Diesel Engine Stanadyne Fuel Injection Pump Replacement & Timing Set

In this EPIC level of detail video we will go over step by step how to replace the Stanadyne DS4 fuel injection pump used on the GM 6.5L V8 diesel engine.
The truck illustrated is a 1999 Chevrolet K1500 Suburban LT, but the parts and procedure will be the same for any 1992 thru 2002 GM OBS C/K truck, van, or Hummer H1 with the 6.5L diesel engine. Chevrolet, GMC, Hummer, and Holden for Tahoe, Yukon, Blazer, H1, Cheyenne, Silverado, Sierra, and Suburban across C1500, K1500, C2500, K2500, C3500, and K3500.
NOTE: Engine timing is required to be reset when performing this repair. You will need a Tech2, or Tech2Win emulator, to perform this timing task. This is the TIME SET procedure shown in the video.
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):
Stanadyne diesel performance formula additive (blue lable): ebay.us/uNZO1b or amzn.to/3Vx424W
Kent-Moore J-41089 / OTC 6087 injection pump wrench set: ebay.us/s8mrHf or amzn.to/3KIi4eL
Kent-Moore J-29872-A injection pump adjustment tool: ebay.us/oFEXuw or amzn.to/3Ru5JP4
Topside creeper: ebay.us/Ke2jnL or amzn.to/3UFtKDx
GM 86362628 (ACDelco 10-4020) rust penetrant: ebay.us/Yfgrng or amzn.to/3ycZSHo
Bolt buster inductive heater: ebay.us/xpyPNp or amzn.to/4btPr0V
19mm flare crowfoot: ebay.us/BH6MfJ or amzn.to/3WyW8dn
19mm line socket: ebay.us/8Dgf2D or amzn.to/3UBiBny
GM 19209059 fuel injection pump: ebay.us/tQJIWq or amzn.to/3Rxl01F
GM 10137486 injection pump gasket: ebay.us/qdqWwO or amzn.to/3XodiuH
GM 14028942 oil filler tube grommet: ebay.us/tYpLOi
Aptiv 12094429 de-pin tool: ebay.us/O38jfm or amzn.to/3yVQhF2
GM 12101854 / ACDelco PT246 optical sensor connector: ebay.us/q2XoJd or amzn.to/4b5Z4lk
GM 14098654 turbocharger oil drain pipe gasket: ebay.us/GbpDlu or amzn.to/4bwyxhC
GM 11514597 turbocharger mounting stud nut: ebay.us/JxbfPy
GM 14098653 turbocharger mounting stud: ebay.us/mb8vJC or amzn.to/44HKvmu
GM 11611439 turbocharger exhaust down pipe clamp: ebay.us/iWJfns or amzn.to/3WxY99D
GM 12531704 lower intake manifold gaskets: ebay.us/trtwMK or amzn.to/4dB18nE
GM 19333512 (supersedes 12346004) pipe sealant with PTFE: ebay.us/qi4XrQ or amzn.to/3QF178k
GM 19369733 (supersedes 12345493) threadlocker red: ebay.us/tuGpoc or amzn.to/3UG165z
GM 10137537 upper intake manifold gasket: ebay.us/yX6B76 or amzn.to/4ahEE8x
Permatex 81158 black silicone sealant: ebay.us/vcxRfx or amzn.to/3UWJ6VS
GM 10154635 (ACDelco TP1256) diesel fuel filter: ebay.us/lcPX1Q or amzn.to/3ygSafc
GM Tech2 scan tool: ebay.us/vLpe5W
GM C/K truck factory service manual: ebay.us/EPGMmC
And if I've saved you some $$ here, consider some coins for the coffee tip-jar! ko-fi.com/drshock
1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002
Chapters:
0:00 - Procedure overview
0:55 - Service manual overview
8:36 - Disconnecting the battery negative terminals
9:14 - Removing the engine cover
9:47 - Removing the upper intake manifold crossover
13:28 - Removing the lower intake manifold
36:44 - Disconnecting the upper radiator hose
41:10 - Relocating the A/C compressor
46:10 - Removing the air box and turbocharger assembly
1:03:52 - Removing the CDR assembly
1:09:25 - Removing the fuel lines
1:17:17 - Removing the injection pump
1:38:06 - Installing the replacement injection pump
1:46:26 - Repairing wiring harness connector(s)
1:47:45 - Reinstalling the fuel lines
1:50:31 - Reinstalling the air box and turbocharger assembly
1:53:10 - Reinstalling the lower intake manifold
1:55:56 - Reinstalling the upper intake manifold crossover
1:57:55 - Bleeding air from the fuel lines
1:58:55 - Performing the TIME SET with a Tech2 scan tool
2:07:57 - Reinstalling the engine cover
#drshock #obstruck #obstrucks
Disclaimer: DrShock, the alias for the human content creator for this UA-cam 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.

[@WingspeedGarage]

Amazing videos as always, thank you 🙏

[@TRUCK_TECHNICIAN]

just so you know the time set function is so you know how close the timing is to do the timing off set relearn , or "TDCO" FOR SHORT, witch you did not do in the video so your timing is not saved in the pcm. the actual relearn can be done with your gm scan tool you have or the koko method. good video though, keep it up. id like to see your tdco numbers in another video

[@DrShock]

Thanks, but that's actually contrary to GM. As I showed in the GM service manual for this model year, GM specifically states *you DO NOT* need to perform a TDCO when replacing just the IP. You ONLY need to perform the TDCO when replacing the crankshaft sensor, or other parts listed. I have another video on setting TDCO, which is a different procedure than time set but similar. You should not perform both procedures, according to GM. Both values are programmed into the PCM by the GM Tech2 tool for either procedure tho.

[@TRUCK_TECHNICIAN]

@@DrShock you always do a tdco when the pump has been replaced I’m a ASE master tech and have done these pumps many times.

[@DrShock]

To each his own. I've been doing GM restorations & service for over 35 years and prefer to only follow the written genuine OEM engineering guidance. ;-)

[@emso0105]

Thanks for the video. My truck is a 1995 with obd1, would you know if the timing process is the same?

[@DrShock]

You’ll still need a Tech2 or Tech2Win tool, but with the OBD1 connector on the cable end. The Tech2 menu layout may vary from what I showed for 1995 and prior. But both Time Set and TDC Learn menu options should be there somewhere. You could also use the older Tech1 tool for 94-95 trucks.

[@jeremiahjackson2137]

You appear to be a very "by the book person" which is fine, but I am curious if your book shows the large bolt that torques the two gears to the front of the camshaft as 75ft lbs, or 126ft lbs? Because there are several books that have this spec incorrectly listed as 75ft lbs. If you look at the size of the bolt, you would assume its 75ft lbs, but its not enough torque, and will allow the cam key to shear. If you would like to check the validity of my statement, grab a gm book, you will see the torque listed as 75ft lbs on 6A6-19, but properly listed as 126ft lbs on 6A6-34. I said that to say this, the book isn't perfect, even the GM ones. When you turn time set on, its a way to monitor the pump position yes, but the computer isn't actually learning anything at that point. Its when you exit time set, you will barely see for a split second the number that the ecm learns when you turn time set off. At this point you will hear the tone of the engine change. Regardless of what the information/book says, if you perform time set, and exit at 3.5-3.7 degrees, turning around and performing tdc learn - which causes the computer to monitor the pumps position to the engine while running for several seconds, it will generate a new TDC number based on the time set number. This is a way for you to verify you have correctly performed the procedure. You can go back to time set, and change the number a tenth or two, and do tdc offset again and see how it reflects in the number. Just trying to help provide some understanding if you are a fan of working on these.

[@DrShock]

Thanks, yes there can definitely be errata in OEM service information. For physical books I recommend that they be kept updated thru the service bulletin system which will periodically issue replacement pages and corrections while the vehicle series is in production for most OEMs. Another approach is to use the online version. Both are available, for a fee, for GM vehicles from www.acdelcotds.com. On using the TDCO relearn function to verify your work during an initial time set, yes, that _optionally_ can bring someone reassurance.

[@danielb-c9100]

what vehicles do you own

[@DrShock]

Just an OBS pickup truck. The vehicles in my videos are customer owned.

[@danielb-c9100]

Are you a gm mechanic?

[@DrShock]

I prefer working on GM vehicles yes. But my day job is as an engineer, these side gig projects are just what I do on my own time.

[@danielb-c9100]

Old video?

[@DrShock]

Nope. Old truck tho.