Hello long time reader of the forum.

I recently rebuilt my 6.5, and installed a used but good low mileage DS4 injection pump on my 97 K3500 things were going well until I drove it. It shook and vibrated terrible at 2k rpm. Its difficult to start on cold startup (even in these warm temps). I could tell the timing was off but didn't know where to start. Long story short after a LOT of reading I discovered that I needed to do Set Time Command.

After finding no local dealers or diesel shops who would work on it or would return calls I purchased a Tech 2 Clone handheld device (its that or sell it). The Clone Tech 2 works great, I was able to see that my TDC time was way off.. I got it sable at 3.5 to 3.6 deg when engine was over 175 deg F. I then did a TDC offset learn from the Tech 2 multiple times as it was varying a bit at first but seemed to settle in between -.35 and -.44.

The odd thing to me is the desired timing and actual timing are still 16.1 to 16.2 at idle. From a few posts here I read after the TDC is set and the TDC offset is good the desired timing should be +8.5deg? I am puzzled why its still at 16 deg after getting things setup correctly with the TCD and TDCO. I think this means that the pump is way off timing which means I need to unbolt the gear from the inj pump and somehow rotate the engine with a wrench either CW or CCW to get the timing inline.

I even did the injector test and turn off and on each one of them one at a time and they are working correctly and the inj pump is sending them fuel.

I did ensure when I set it up that the marks on the crankshaft timing chain gear and the camshaft gear were aligned properly and then rotated the engine CW until the crankshaft timing gear was at 12, the camshaft timing chain gear was at 12 and the injection pump was at 6. The inj pump timing gear and inject pump gear were exactly inline with each other.

As there are no local mechanics around here that will touch the 6.5 I'm on my own.. Any ideas?

Thank you for the help


Here are the numbers and other information:

Miles on engine 15 Totally rebuilt
Actual timing at idle 16.1 deg
Desired timing at idle 16.2
TDCO -.35 deg

Clear tubing on inj pump return and there are no air bubbles