Major fuel problem???

I have a 1997 Chevrolet Suburban with a 6.5 liter turbo diesel engine with 235k miles on it. Lately I've been having problems with it just dying-out on me, especially when I pick the kids up at school or on the way home from church. Examples over the past two months:

1) Hard to start. But once it starts, which is most of the time, it will idle for up to 20 seconds then just die on me. Other times it will run fine for up to 20 miles, then start "surging" on me in traffic, then it will completely die at a traffic light. Sometimes then I have to restart it several times, only to have it die on me as I push on the pedal... then it will run fine again. (the transmission runs fine, so I believe its not the problem).

I've had a mechanic student over here trying to help but its costing me a lot to find this problem! The first thing replaced was the fuel filter, which came out black and utterly filthy! ...I felt so happy to think that such a simple thing could fix my truck....but the next day I learned my problem was not solved!...Next he replaced a relay switch under the hood (located on the driver's side of the engine). The first thing I noticed is that the turbo once again began to work, but the darned vehicle started acting up again the very next day....Then a couple weeks later he decides its the in-line fuel pump/regulator thingie, and its replaced (Its the pump under the truck, along the frame rail, directly below the driver's seat).....But I'm still having a problem!

A few miserable days passed and I replaced the fuel cap at the recommendation of a neighbor...problem not fixed.... Today I checked for any cracks in the fuel line but didn't see or feel any. I've even checked the fuel relay fuse inside the fuse box. Anyone have suggestions?

I hope its not the injector pump which costs over 1k. It's a bit too expensive to buy right now. Thanks ahead of time for any help!

You need to take it to A Chevy Dealer and pay to have it check out (a lot cheaper then replaceing good parts) There is a problem with the ign switch on k trucks causing them to shut down but I dont think that would cause a diesel to shut off.
You said the fuel filter was very dirty ?? Run some diesel fuel cleaner in it because there might be a lot of dirt in the injector pump.
All the diesel problems I worked on had injector pump problems. I would try using a good aftermarket fuel cleaner (2 tanks full) and see what happens.
Not to many people know how to work on a diesel and I would still think about having a Pro looking at it.
Does it blow out a lot of black smoke on start up after it shuts down?? How is the air cleaner (very important in a diesel)

There are two things i would check out. I have exactly the same set up as you although mine is a 4x4 with 160k. When I removed the fuel filterI found sludge in my filter bowl also. I took the filter bowl out and found that the stand tube in it (this is the water fuel seperator) had rusted away. because of this the fuel wasn't getting filtered properly. I replaced it with a new one for around 100 bucks. I also replaced the pmd and mounted it remotely with a heat sink. for around 300 or 400. If you look around the 6.5 diesel web sites you'll see that that electronic gizmo is the nemisses of the engine. Hope this helps.Rich

FSD/PMD is a common problem.

So are bad grounds/connections, and ignition switches.

Visit www.thedieselpage.com.

Tons of information there.

I have had the same problems with my '02 chevy suburban. I hooked it up to a machine and the fuel compisition sensor code spit out twice, so I took it to the shop and they say they dropped the gas tank and changed it. I picked it up and the next day I drove about an hour to the beach with the kids and on the way there and back it broke down 6 times. It will die going slow, fast, turning corners, going straight, with alot of gas, low on gas, pretty much anything. We did change the fuel filter to begin with, didnt work. Also had a friend behind me going to the beach and they said when it started again black smoke spit out. We do not really know what to do next. Spent alot fixing it last time, for it to still be broken. I know that it is a 5.3 liter with v8 vortec. Any advice would help!!! Thanks

I have had the same problems with my '02 chevy suburban. I hooked it up to a machine and the fuel compisition sensor code spit out twice, so I took it to the shop and they say they dropped the gas tank and changed it. I picked it up and the next day I drove about an hour to the beach with the kids and on the way there and back it broke down 6 times. It will die going slow, fast, turning corners, going straight, with alot of gas, low on gas, pretty much anything. We did change the fuel filter to begin with, didnt work. Also had a friend behind me going to the beach and they said when it started again black smoke spit out. We do not really know what to do next. Spent alot fixing it last time, for it to still be broken. I know that it is a 5.3 liter with v8 vortec. Any advice would help!!! Thanks

You should start a new thread...as people reading this thread are looking at a totally different engine setup.

POst a new thread and given all the issues you say..I assume your check engine light is on now?

no it went off when they changed the sensor. waiting for it to come back on, everyone says thats all we can do.

no it went off when they changed the sensor. waiting for it to come back on, everyone says thats all we can do.

this post is 6years old ...you must start a new posting with " YOUR ISSUES "

give the full vehicle details ...also any specific codes pulled and the issues you have ...

mine did the same thing found out it was the (pmd)a.k.a pump mounted driver or fsd that is located on the injection pump major repair, but this advice will save you some $ you can relocate the pmd without removing the intake plenum just simply unplug the harness and fish it up with a coat hanger(thats what i used) being careful not to damage plug this way you wont have to take it to a gm dealer to time it. 2. go to the diesel store .com and they will guide you in right direction of coarse they will try to tell you to buy the whole aftermarket kit which is very pricey,so what i did is kept searching the site and found a used one for 50.00 also purchased the wire harness with the #9 replacment chip which is needed and moved the pmd to the firewall which keeps it cooler because heat=overheating within the pmd all reality the pmd is the electronic fuel injection for the 6.5 it can not run or will not run with out it and will stall and or shut off like getting no fuel at all. one experianced 6.5 owner