i appreciate any input from you guys.


okay so i've finally dug my old 1996 6.5 Turbo 4x4 out of 2 feet of snow.

took two brand new batteries to get the thing fired over, got it unstuck, then came my problems.


one of my fuel injector return lines has gone missing from the drivers side and is pissing fuel everywhere while the engines running. just to keep the engine running i've plugged the nipple the was pissing fuel. should not be a big deal, return line kit already ordered. just wondering if this rig i have set up is hurting the engine? i'm just moving it around with the set up shown. that hose with the gear clamp is plugged six inches down.

second, turbo is not spooling. i have a second turbo set up that i plan to replace the seized one with. is there any gaskets i should replace before bolting the new one on?

third, temp gauge in the dash is not working. i found a little blue sensor on the drivers side of the engine block with a greenish wire beside it. the wire is busted off the blue 'sensor'. is that my temp gauge sensor? and where do i find a replacement.. (GM part #??)

fourth, very slow coolant leak coming from somewhere. it looks like it's from the rad, but when i parked it last year the rad did not leak. replaced a gear clamp on the upper house that was leaking as well. i'm puzzled.

fifth, when you push the brake pedal in, the system feels like it's dry. it's really soft and easy to push in. lots of play in the pedal before the brakes engage and when they do engage, it's quick and rather violent. brake fluid reservoir is full. brake warning like it on. time to change them?

finally, glow plugs are cycling. from cold or warm doesn't matter, WTS light cycles on and off in slow flashes. my guess is a relay or controller of some sort, but figured i'd hear what you guys have to say.


thanks in advance for any input, you guys are always great help.

 

Tygon line from your local small engine guy would do for return line shut since you have the kit coming?
Plugging the return at the frt of the engine won't hurt-it just means that entire bank of cylinders that are not connected will return from the open injector and leak everything that's returned there from all 4 cylinders.

There is only a gasket used on the oil return flange under the turbo-all exhaust mating surfaces are metal to metal-no gaskets.

Yes the drivers side frt cylinder head sensor is for the temp gauge.

Coolant leaks require a pressure test.

Glow relay sounds like a good place to start for cycling glows,but theses engines need glow plug assistance to start at all times-just the duration changes.

As far as brakes go-I would be looking for a bad brake line even if the reservoir is full-could be a balooning flex line?

 

is this the proper gasket for the return flange? http://bit.ly/1i0n4qU

and i'm not sure where to find a replacement for that blue temp sensor.

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and what size tygon line would i ask for?

 

Take a piece of the old line with you so they can match it up,marine repair would likely also have it.

The temp sensor can be had from rockauto or any dealer,or Bensons in Port Perry since they are delco distributors.
Delco # 21377
GM # 25037332

Looks more like you just need the wiring pigtail for the sensor though:
Delco # PT728
GM #12126458

Thats a good gasket kit but the metal gasket is not used from the factory-if the manifold is badly pitted you might need the metal gasket?

 

sorry for the prolonged update.

okay. first off, a temporary fix for the lines coming in this week for the injectors. no leaks and i'm happy with it for a couple days.

second, rigged this puppy up for the temp now the gauge work perfect.

as for the brakes, found a pin hole leak that last pressure while it sat for the time it did. found two couplings in the line and replaced it and front callipers and pads for the heck of it. .

ordered new injectors and glow plugs+controller and cdr valve kit to put in this old girl.

found a potentially big problem though. i can't see any wires for a glow plug for this cylinder or a head for the actual glow plug.. potentially snapped ? driver's side injector closest to the firewall.

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oh and waiting on a turbo solenoid. gonna try and switch that out and see what happens. wastegate moves free and took the intake off the turbo and the wheels spins like new. either a vac line or the solenoid i'm thinking.