2003 Suburban 5.3L No. 6 Cyl Misfire after Intake Gasket and Fuel Pump Replacement

BearClaw

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Hello all,

This is my first post and I look forward to seeing what everyone has to say.

BLUF: 2003 Suburban 5.3L Flex has Cylinder No. 6 Misfire. Check engine light is off until accelerating and then the check engine light blinks. Check engine lights turn off when slowing down.

Background:

  • The truck would not start, it would crank but would not turn over until after several seconds cranking. I tested fuel pressure. With key on, it would build pressure at the rail, but then it would quickly loose pressure. I replaced fuel filter first, but no change

  • I changed upper intake manifold gasket, knock sensors, knock sensor harness, valve cover gaskets, and water channel seals. I turn the truck on and backed it out of the garage and around the house and turned it off. I tried turning it back on but it would only crank. I tried turning it on and let it crank for 15-20 seconds until it finally sputtered and groggily turned over. I had to give more fuel in order for it to start running smoothly. Truck ran but it had a knock sensor code.

  • I warrantied the Delphi knock sensors and replaced them with AC Delcos. I pulled intake manifold and replaced it.

  • I replaced the fuel pump couple days later to address the initial start-up issue in No. 1 point of this list. It fixed the startup issue.

  • Now, the truck runs but has misfire in No. 6 cylinders.
    • I checked plugs. Couple plugs have oil on threads. Gaps are good. I moved spark plugs from No. 6 to No. 4. Code did not follow plugs.
    • I checked coils. Swapped plugs back and then swapped coils from No. 6 to No. 4. Code did not follow coils.
    • I checked injectors. Swapped coils back and then swapped injectors from No. 6 to No. 2. Code did not follow injectors.
    • I sprayed around intake and vacuum hoses with cleaner but there is no reaction from engine.

  • Additional information: Truck has around 240k miles. Truck has had a P0420 code for Catalyst System Efficiency Below Threshold Bank 1 for a year or so. I do not know if this is a clogged cat as there hasn’t been a misfire until messing with intake and fuel pump.
In the end, I’ve made repairs on fuel and air systems and I’m running out of ideas. Any suggestions would be much appreciated.
 
Hello all,

This is my first post and I look forward to seeing what everyone has to say.

BLUF: 2003 Suburban 5.3L Flex has Cylinder No. 6 Misfire. Check engine light is off until accelerating and then the check engine light blinks. Check engine lights turn off when slowing down.

Background:

  • The truck would not start, it would crank but would not turn over until after several seconds cranking. I tested fuel pressure. With key on, it would build pressure at the rail, but then it would quickly loose pressure. I replaced fuel filter first, but no change

  • I changed upper intake manifold gasket, knock sensors, knock sensor harness, valve cover gaskets, and water channel seals. I turn the truck on and backed it out of the garage and around the house and turned it off. I tried turning it back on but it would only crank. I tried turning it on and let it crank for 15-20 seconds until it finally sputtered and groggily turned over. I had to give more fuel in order for it to start running smoothly. Truck ran but it had a knock sensor code.

  • I warrantied the Delphi knock sensors and replaced them with AC Delcos. I pulled intake manifold and replaced it.

  • I replaced the fuel pump couple days later to address the initial start-up issue in No. 1 point of this list. It fixed the startup issue.

  • Now, the truck runs but has misfire in No. 6 cylinders.
    • I checked plugs. Couple plugs have oil on threads. Gaps are good. I moved spark plugs from No. 6 to No. 4. Code did not follow plugs.
    • I checked coils. Swapped plugs back and then swapped coils from No. 6 to No. 4. Code did not follow coils.
    • I checked injectors. Swapped coils back and then swapped injectors from No. 6 to No. 2. Code did not follow injectors.
    • I sprayed around intake and vacuum hoses with cleaner but there is no reaction from engine.

  • Additional information: Truck has around 240k miles. Truck has had a P0420 code for Catalyst System Efficiency Below Threshold Bank 1 for a year or so. I do not know if this is a clogged cat as there hasn’t been a misfire until messing with intake and fuel pump.
In the end, I’ve made repairs on fuel and air systems and I’m running out of ideas. Any suggestions would be much appreciated.
Did you do a compression test?
 
Did you do a compression test?
Well, I am embarrassed. Thank you for the reply.

I realized that I swapped wires to see if the code will follow, but I never swapped the ignition coils. I swapped the No. 6 coil with No. 4 and the code did follow. I bought a new coil, replaced it, and it seemed to have solved the misfire.

I made this repair shortly after posting this and hadn’t updated. Thank you again for taking the time to read my post.
 
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