Bought the truck about 2 months ago. It was surging and than quit starting all together unless it was cold.

REPLACED:
In-Line Fuel Pump
Fuel Filter

Still wouldn't start.

REPLACED:
PMD
Resister Chip
Added extension/relocation harness

Now running, but still horribly surging. Put it on computer, pulled MAP Sensor code.
REPLACED:
Map Sensor (cross-over? Map Sensor plugs are '96 not '97)

Still Surging. Took to local Chevy dealer, diagnostics pulled: vacuum pump & injector pump.
REPLACED:
Injector Pump (The way the fuel lines were hooked up and how we hooked them back up does NOT match. We used the diagram to hook them back up.)
Upper & Lower Manifold Gaskets
Vacuum Pump
Quick Release Hose Clamp for hose off of Heater Core (snapped in 1/2 during reassembly)

Put it all back together and now it won't even start!
Cranks, but doesn't sound right. We are getting diesel through the fuel pump, fuel filter, fuel lines (not much) and purge valve. Pulled it apart again to check "timing" Upper and Middle gear are right, not sure how to get to Back Middle and Lower Gear. This portion did NOT have a gasket, we have bought it to put in though. Had a mechanic that was suppose to be helping, he has went MIA. This truck is my families livelyhood. We have been down for 2 weeks straight. Need it up and going.

Also, when I turn key over for glow plugs, they "click" is this a sign that the cylinoid may be going out? The light comes on solid, then goes off, then flashes about 5 times and then goes off permanently. I wait till it is completely off before starting.

Put $1,500 down and financed $6,000 (total $7,500). Have made 2 payments totalling $600 and spent $2,7?? in repairs.... grr.

If you have real honst help, PM me and maybe we can exchange #'s for more reliable communication, as I will be mobile after this. As I have googled for help for this truck I have found this site is very active and offers alot of advice.

---AutoMerged DoublePost---

Found on another site: pull the fuse for the ECM and pull off one of your glowplug connectors off of the glowplug and just ground it out. then plug it back in and put the fuse back in. this will reset your glowplug com. it should fire right up then.
good luck

Read more: 97 6.5L Turbo Diesel won't start Page1 - Diesel Power Forums at Diesel Power Magazine

 

Do not do anything you read there with the glow plugs,the system is working properly as far as the relay and ECM control,glow light are concerned-I don't kniow if power is making it to all 8 glow plugs or not during the time the wait to start light is lit since you haven't indicated that you checked that yet?
Also are the glow plugs any good-since it started before the IP replacement they are likely ok?

In any event they will do little to no good since you are not starting the truck correctly-begin cranking as soon as the wait to start light goes out the first time.
The additional flashes of the light are called afterglow and are meant to happen when the engine is running.

My first question about the IP replacement is dd the IP/PMD harness ground remain fastened under an optical sensor screw on top of the IP or did you move it anywhere else?

Also please describe how the fuel lines are currently connected vs the way they were-it is important that you explain this more clearly.

 

Thank you for explaining that. This is the ONLY diesel I have ever driven that did it.

My father and now the MIA mechanic are back to working on it. I do not know about the ground. I mentioned it to both of them and neither seemed concerned about it as we continued to take apart the front end to get to the timing gears. In the process we discovered that I am in desperate need of a new timing chain and the mechanic suggested a crank sensor.
As we undid all the fuel lines, my mother marked them from the first one she could see standing on the passenger side 1-8, going around over the top, leaving 7 & 8 on the bottom. When my father attempted to hook them back up he swore she had messed one up and insisted on getting the diagram from Chevy. The way my mom undid them left the front passenger pair as 1 & 4, but the diagram counted them as 1 & 3. Unfortunately, because my dad took all the markers off, these are the only 2 my mother and I can remember where are. I contacted chevy again, and asked for a '96 Diagram, but as far as I can tell they are the same, since we have come to the conclusion that the truck is a cross over.

REPLACING: (Tomorrow)
Crank Sensor
Timing Chain

 

All injector lines for all 6.2 and 6.5 connect the same way to the IP for firing order-page 35.
The manual I linked you to in PM should show the correct routing.

You also have the cylinder numbering incorrect, the cylinders are numbered like so:
1 2
3 4
5 6
7 8

 

Im talking about the hard fuel lines, not the cylinders.

 

I know and thats what I answered your question as,the frt passenger side pair of cylinders is not 1,3-its 2,4 is what I am trying to get across to you.

Did you download the military manual I linked you to in the private message I sent?
All the info for hard line placement is there on page 35.

 

I currently cant download it. The fuel line to IP diagram we used was straight from Chevy. So why would they be different?

 

You have to join that site to download-it is a great forum as is this 1.

Here is the page for comparison:

 

Did that diagram jive with what you have already and did it help at all?

 

New timing chain and crank sensor, put back together, started, even idled on its own...changed oil, put in antifreeze and then wouldnt start....ideas?