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): https://ebay.us/uNZO1b or https://amzn.to/3Vx424W

Kent-Moore J-41089 / OTC 6087 injection pump wrench set: https://ebay.us/s8mrHf or https://amzn.to/3KIi4eL

Kent-Moore J-29872-A injection pump adjustment tool: https://ebay.us/oFEXuw or https://amzn.to/3Ru5JP4

Topside creeper: https://ebay.us/Ke2jnL or https://amzn.to/3UFtKDx

GM 86362628 (ACDelco 10-4020) rust penetrant: https://ebay.us/Yfgrng or https://amzn.to/3ycZSHo

Bolt buster inductive heater: https://ebay.us/xpyPNp or https://amzn.to/4btPr0V

19mm flare crowfoot: https://ebay.us/BH6MfJ or https://amzn.to/3WyW8dn

19mm line socket: https://ebay.us/8Dgf2D or https://amzn.to/3UBiBny

GM 19209059 fuel injection pump: https://ebay.us/tQJIWq or https://amzn.to/3Rxl01F

GM 10137486 injection pump gasket: https://ebay.us/qdqWwO or https://amzn.to/3XodiuH

GM 14028942 oil filler tube grommet: https://ebay.us/tYpLOi

Aptiv 12094429 de-pin tool: https://ebay.us/O38jfm or https://amzn.to/3yVQhF2

GM 12101854 / ACDelco PT246 optical sensor connector: https://ebay.us/q2XoJd or https://amzn.to/4b5Z4lk

GM 14098654 turbocharger oil drain pipe gasket: https://ebay.us/GbpDlu or https://amzn.to/4bwyxhC

GM 11514597 turbocharger mounting stud nut: https://ebay.us/JxbfPy

GM 14098653 turbocharger mounting stud: https://ebay.us/mb8vJC or https://amzn.to/44HKvmu

GM 11611439 turbocharger exhaust down pipe clamp: https://ebay.us/iWJfns or https://amzn.to/3WxY99D

GM 12531704 lower intake manifold gaskets: https://ebay.us/trtwMK or https://amzn.to/4dB18nE

GM 19333512 (supersedes 12346004) pipe sealant with PTFE: https://ebay.us/qi4XrQ or https://amzn.to/3QF178k

GM 19369733 (supersedes 12345493) threadlocker red: https://ebay.us/tuGpoc or https://amzn.to/3UG165z

GM 10137537 upper intake manifold gasket: https://ebay.us/yX6B76 or https://amzn.to/4ahEE8x

Permatex 81158 black silicone sealant: https://ebay.us/vcxRfx or https://amzn.to/3UWJ6VS

GM 10154635 (ACDelco TP1256) diesel fuel filter: https://ebay.us/lcPX1Q or https://amzn.to/3ygSafc

GM Tech2 scan tool: https://ebay.us/vLpe5W

GM C/K truck factory service manual: https://ebay.us/EPGMmC

And if I've saved you some $$ here, consider some coins for the coffee tip-jar! https://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 YouTube 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.