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Thread: metal in filter housing

  1. #1
    Join Date
    Mar 2009
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    Folsom, CA
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    Default metal in filter housing

    Any thoughts on how I could get little flakes of what seem like aluminum (they're not magnetic) in the filter housing. My thoughts are the lift pump ate itself. Unfortunately I didn't notice them when I replaced the filter and it seems like they got into some if not all of my injectors. Causing at least one to overheat and melt the glowplug.
    Mike
    1994 K2500 Suburban 320,000 mi., F VIN, 4L80E, 3.73 w/posi., 3" turbo back, no cat, FSD Heat Sync, #9 resistor, SSD heads, SSD intake, fuel miser injectors, Bastard IP (5068), 4x4 posi (manual front axle lock), Cooling upgrade w/duel 180 t-stats and d-max fan

  2. #2
    Join Date
    Feb 2007
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    2,962

    Default

    A glow plug will only melt from electric burn out, a sign of a bad plug, unless they all burn out, meaning over timed, had that on my 1982. When I bought the GMC truck, it came with fine aluminium flakes in the fuel system. It was dropped off for me to collect, and it would not run. The flakes got through the filter and jammed the IP, which had to be replaced, the injectors were not affected. I cleaned the filter housing with rag, replaced the filter and put an extra filter in the line, got the unit from a marine supply. I recently had the fuel tank out and open, the flakes are in there, I have no idea where they came from. I hope this helps your mystery.
    Last edited by grancito; 01-13-2023 at 12:44 PM.
    Grant H.
    1995 6.5 turbo GMC K2500 extra cab 4x4 pickup, PMD under bumper, mechanical wastegate, 228,000 miles, rebuilt engine, 4.10 diff, 16 mpg
    1994 6.5 turbo GMC K2500 4x4 suburban #9 resistor, PMD in the bumper, mechanical waste gate, 226,000 miles, new engine, 0 miles. 3.73 diff, 16 mpg
    1982 4x4 shortbed 6.2 Chev 260,000 miles untouched motor 17 MPG 4.27 diff. Best thing I ever owned, since 1992.

  3. #3
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    Mar 2009
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    Folsom, CA
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    Default

    Thanks Grant. I did add a filter after the factory one. Looks like I’ll be dropping my tank soon to investigate.
    Mike
    1994 K2500 Suburban 320,000 mi., F VIN, 4L80E, 3.73 w/posi., 3" turbo back, no cat, FSD Heat Sync, #9 resistor, SSD heads, SSD intake, fuel miser injectors, Bastard IP (5068), 4x4 posi (manual front axle lock), Cooling upgrade w/duel 180 t-stats and d-max fan

  4. #4
    Join Date
    Feb 2007
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    Default

    You will need help to hold the tank, even empty it will be heavy. It is bigger than my truck tank, that is heavy, I used the transmission jack, and did the job without help. Clean the end of the filter sock if it has a relief valve, mine was plugged with the flakes, seems like the sock blocked, so the fuel bypassed through it.
    Last edited by grancito; 01-14-2023 at 01:51 PM.
    Grant H.
    1995 6.5 turbo GMC K2500 extra cab 4x4 pickup, PMD under bumper, mechanical wastegate, 228,000 miles, rebuilt engine, 4.10 diff, 16 mpg
    1994 6.5 turbo GMC K2500 4x4 suburban #9 resistor, PMD in the bumper, mechanical waste gate, 226,000 miles, new engine, 0 miles. 3.73 diff, 16 mpg
    1982 4x4 shortbed 6.2 Chev 260,000 miles untouched motor 17 MPG 4.27 diff. Best thing I ever owned, since 1992.

  5. #5
    Join Date
    Mar 2009
    Location
    Folsom, CA
    Posts
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    Default

    So I haven't dropped the tank yet, not really looking forward to or in a hurry.

    Right now I'm trying to flush the IP. It seems like the flakes didn't plug it up because it ran before tearing into it. The reason I took it apart is because it was smoking pretty bad. Took the injectors apart and found one that was plugged with metal flakes but all the rest were clean, at least visually. Back to flushing the IP... I have everything hooked up except the hard lines and return lines are not connected to the injectors. I have clear tubing to direct the spray from the engine so when I crank it over I get no fuel out the injector lines. I have bled the air out of the stock filter and run fuel through the secondary filter. What am I missing?
    Mike
    1994 K2500 Suburban 320,000 mi., F VIN, 4L80E, 3.73 w/posi., 3" turbo back, no cat, FSD Heat Sync, #9 resistor, SSD heads, SSD intake, fuel miser injectors, Bastard IP (5068), 4x4 posi (manual front axle lock), Cooling upgrade w/duel 180 t-stats and d-max fan

  6. #6
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    Feb 2007
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    While reading your post, in which the wording has me confused, it did give me a brain wave, as to where the flakes are coming from, and as in both our cases, not stopped by the filter, but are in the tank. They are made in the IP, and go through the return line to the tank. The first stage of the IP is a vane pump, I wonder what the cylinder is made of. I think I understand what you are doing and can't think of why there is no injection. I am going to look for the phone number of the supplier of my IP, he was helpful and may be able to answer the aluminium flake mystery.
    Grant H.
    1995 6.5 turbo GMC K2500 extra cab 4x4 pickup, PMD under bumper, mechanical wastegate, 228,000 miles, rebuilt engine, 4.10 diff, 16 mpg
    1994 6.5 turbo GMC K2500 4x4 suburban #9 resistor, PMD in the bumper, mechanical waste gate, 226,000 miles, new engine, 0 miles. 3.73 diff, 16 mpg
    1982 4x4 shortbed 6.2 Chev 260,000 miles untouched motor 17 MPG 4.27 diff. Best thing I ever owned, since 1992.

  7. #7
    Join Date
    Mar 2009
    Location
    Folsom, CA
    Posts
    216

    Default

    I guess, ultimately, I would like to know if there is a way that the DS4 can wear in a way that it will release aluminum or other metal into the injectors or, if it does wear this way, would it all go to the tank?
    Mike
    1994 K2500 Suburban 320,000 mi., F VIN, 4L80E, 3.73 w/posi., 3" turbo back, no cat, FSD Heat Sync, #9 resistor, SSD heads, SSD intake, fuel miser injectors, Bastard IP (5068), 4x4 posi (manual front axle lock), Cooling upgrade w/duel 180 t-stats and d-max fan

  8. #8
    Join Date
    Feb 2007
    Posts
    2,962

    Default

    Most of it would go to the tank. I am waiting on a reply from Pensacola Fuel about the wear possibility.
    Grant H.
    1995 6.5 turbo GMC K2500 extra cab 4x4 pickup, PMD under bumper, mechanical wastegate, 228,000 miles, rebuilt engine, 4.10 diff, 16 mpg
    1994 6.5 turbo GMC K2500 4x4 suburban #9 resistor, PMD in the bumper, mechanical waste gate, 226,000 miles, new engine, 0 miles. 3.73 diff, 16 mpg
    1982 4x4 shortbed 6.2 Chev 260,000 miles untouched motor 17 MPG 4.27 diff. Best thing I ever owned, since 1992.

  9. #9
    Join Date
    Feb 2007
    Posts
    2,962

    Default

    I gave up waiting for a reply from Pensacola Fuel Injection and phoned them, the guy was a bit vague and said that they did not receive many IPs full of flakes, but some. He said that the vane supply pump has some kind of alloy bore but did not know what alloy, and when it wears bad it fails to deliver enough fuel to be injected. He agreed that the ultra low sulphur fuel can cause a lot of wear, and many people use a lubricant additive, some use 2 stroke oil. I think that you are in for a new/rebuilt IP. I paid $475 for one from them, 8 years ago, through Ebay.
    Grant H.
    1995 6.5 turbo GMC K2500 extra cab 4x4 pickup, PMD under bumper, mechanical wastegate, 228,000 miles, rebuilt engine, 4.10 diff, 16 mpg
    1994 6.5 turbo GMC K2500 4x4 suburban #9 resistor, PMD in the bumper, mechanical waste gate, 226,000 miles, new engine, 0 miles. 3.73 diff, 16 mpg
    1982 4x4 shortbed 6.2 Chev 260,000 miles untouched motor 17 MPG 4.27 diff. Best thing I ever owned, since 1992.

  10. #10
    Join Date
    Mar 2009
    Location
    Folsom, CA
    Posts
    216

    Default

    I was looking at the service manual for the DS4 and from what I could tell it looks like it is a one way flow of residual pressure from both the injectors and the injection side of the pump to the return line.

    Link for DS4 for anyone who want it is here: http://www.stanadyne.com/dealerporta...nual/99646.pdf

    Thanks for your help on this, Grant. I’ve seen replacements from $700-$1700. So I’ll start saving my pennies (or pesos where you are). ��
    Mike
    1994 K2500 Suburban 320,000 mi., F VIN, 4L80E, 3.73 w/posi., 3" turbo back, no cat, FSD Heat Sync, #9 resistor, SSD heads, SSD intake, fuel miser injectors, Bastard IP (5068), 4x4 posi (manual front axle lock), Cooling upgrade w/duel 180 t-stats and d-max fan

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