air noise at heavy load

[AStewart]

I would never have thought the sound would have been that loud fro the intercooler.

 

[AStewart]

Here are some pics of the new cooler.

 

[bmoeller]

They can be loud from where ever they originate. Last time I went to TX, I had 2 leaks to deal with. Bad CAC boot and loose manifold bolts.

 

[RShipp]

Glad to hear that you found the problem easily. Dad's truck has the plastic aftercooler. He keeps his stock though.

 

[AH64ID]

Is that right? Hmmm. That's funny. Explain this then, "expert". Why when I'm towing with a friend of mine's 05, with all stock components with a set of gauges, does the exhaust temp climb until 1400 and then the boost go from 30 to 42 psi and the egts stay the same. What do you think the electrical actuator does on the turbo? Why would the turbo have a diaphram and an electronic actuator. Huh? High egts is not how Cummins meets emissions. The way they meet emissions is to draw out the combustion process so it doesn't flash. A quick flash creates excess NOx. If you draw out the burn you cut down on the NOx. They do this by retarding the timing and having pilot and post injections.

Sorry. . thats just not the case. 42psi on a stock truck would set an overboost code. The electronic actuator is there because the WG itself is a 22psi unit, so the actuator allows more precise control, and to exceed 22psi.



I would say that something is wrong with your buddies boost gauge, a stock motor doesn't even burn enough fuel for 42psi.



Do yourself a favor and do some research, and take a look under the hood. . there is NO EGT sensor ANYWHERE on the truck. .

 

[Ducman82]

ya i agree. no way stock motor can do 42 psi, it does not have the fuel, the turbo, or the computer settings for that. not to mention head studs would be needed around that point.

 

[RShipp]

ya i agree. no way stock motor can do 42 psi, it does not have the fuel, the turbo, or the computer settings for that. not to mention head studs would be needed around that point.

Stock head gasket holds 60psi

 

[JBallou]

No head studs are needed for 42 psi. the rest is correct.

 

[RShipp]

Sorry. . thats just not the case. 42psi on a stock truck would set an overboost code. The electronic actuator is there because the WG itself is a 22psi unit, so the actuator allows more precise control, and to exceed 22psi.



I would say that something is wrong with your buddies boost gauge, a stock motor doesn't even burn enough fuel for 42psi.



Do yourself a favor and do some research, and take a look under the hood. . there is NO EGT sensor ANYWHERE on the truck. .

So why would Cummins have two different ways to actuate the wastegate? What tells the electronic acuator to increase boost? Why wouldn't the turbo just have a 30psi wastegate like the HX35s have? Do yourself a favor and get a ISB 5. 9L CR service and tech manual, or search on quickserve online for the engine searial number. Lots of electronic publications there.

 

[cerberusiam]

ya i agree. no way stock motor can do 42 psi, it does not have the fuel, the turbo, or the computer settings for that. not to mention head studs would be needed around that point.

Stock fueling with a boost fooler will net you 42 psi if you stay in it till redline at 3200 rpm's. The stock motor components and HG can easily handle that if EGT's stay in check. HG are good to about 50 psi then you are pushing the limits, 60 psi is a problem waiting to happen.

Is that right? Why when I'm towing with a friend of mine's 05, with all stock components with a set of gauges, does the exhaust temp climb until 1400 and then the boost go from 30 to 42 psi and the egts stay the same. What do you think the electrical actuator does on the turbo? Why would the turbo have a diaphram and an electronic actuator. Huh? High egts is not how Cummins meets emissions. The way they meet emissions is to draw out the combustion process so it doesn't flash. A quick flash creates excess NOx. If you draw out the burn you cut down on the NOx. They do this by retarding the timing and having pilot and post injections.

With stock fueling and no boost fooler you will hit 30-32 psi and hold long before EGT's top at 1400. Same with a BF, you will max boost then EGT's will climb to max a lot slower. If that is not happening the tune is not a stock or there is another issue.



The 5. 9 has no EGT sensor anywhere. Cummins testing felt it was not needed with the boost and fueling the engine has as delivered.



The acutator on the turbo is for the WG and it modulates the WG to keep boost at around 30 psi max. The spring in the stock WG is preset at 26 psi and the WG controller bleeds boost of the compressor side of the turbo to hold the WG closed until 30 psi is reached. The boost is read by the ECU from the MAP sensor and the WG controller reaxts to it thru the ECU.



The ECU uses boost, rpm's, and intake air temp to determine fueling rates across the rpm's. It does not care what the EGT temp is otherwise you could not burn one of these engines down.



Emisions are accomplished with several factors, injection timing, cam timing, and multiple injection events, and in-cylinder EGR. This limits cylinder temps to cut down the creation on NOX which occurs at higher temps.



Diesel fuel does not flash like gasoline, it burns at a fairly steady rate across a wide range of heat and pressure.



You need an FSM for these trucks to understand how they programmed them and how they react. Specs on turbos are only good for ball park figures, you need them in the application to understand how they are functioning.

 

[Motorhead]

So was the intercooler covered under warranty??

 

[AH64ID]

So why would Cummins have two different ways to actuate the wastegate? What tells the electronic acuator to increase boost? Why wouldn't the turbo just have a 30psi wastegate like the HX35s have? Do yourself a favor and get a ISB 5. 9L CR service and tech manual, or search on quickserve online for the engine searial number. Lots of electronic publications there.

Why don't you do yourself the favor (I have read the service manual)... . Find anything on the motor that can read EGT and i'll succeed. . but its just not there. . I have attached the ECM inputs.







I don't know why they went electronic on the actuator, probably precision. But there is not 2 different ways to actuate it, just one. The elec solenoid opens ~32psi and sends air to a WG that needs 22psi to open... So sending more air to the WG than is needed to open it means that it will open at the psi they want it to open at.

 

[AH64ID]

Stock fueling with a boost fooler will net you 42 psi if you stay in it till redline at 3200 rpm's. The stock motor components and HG can easily handle that if EGT's stay in check. HG are good to about 50 psi then you are pushing the limits, 60 psi is a problem waiting to happen.

I have never come close to 42 psi with stock fueling, highest I have gotten is 37. Even with 14-16K in tow yesterday I couldn't break 35, WOT in 4th, and it takes a while to get there with that much weight. DP hits 50 about the same time rpm's hit 2900 and the defuel brings the boost back to 30 NOW!!. . I also noticed a drop in boost at about 50-54 DP at 2800 rpms, so i don't know if the tach was reading slow, as its ECM controlled, or if the WG blew open at that much DP.

 

[AStewart]

No. They said it is under the 3/36 and I picked up a rock or something to put a hole in it. Go figure... it could not be the cheap plastic tanks!!! I will write a letter but who do I send it too Fiat????? It should be covered under the emmisions because it started puking smoke.

 

[cerberusiam]

I have never come close to 42 psi with stock fueling, highest I have gotten is 37. Even with 14-16K in tow yesterday I couldn't break 35, WOT in 4th, and it takes a while to get there with that much weight. DP hits 50 about the same time rpm's hit 2900 and the defuel brings the boost back to 30 NOW!!. . I also noticed a drop in boost at about 50-54 DP at 2800 rpms, so i don't know if the tach was reading slow, as its ECM controlled, or if the WG blew open at that much DP.

Not loading the engine enough in 4th to demand max fueling. If all you got was 2900 rpm's then defueled you won't see 40 psi.



With the stock TC and 10k in tow mine would top 40 psi on every grade between Ontario and Pendelton. It would fuel all the way to redline at 3200 rpms and then boost would drop just under 40 psi. About 3100 rpms it would just tocuh 42 psi and hang there until the engine defueled.



Incidently the DP gauge had been pegged at 60 psi for a while and there wasn't any drop in boost. Every truck is a little different and they seem to react a bit different.

 

[AH64ID]

Not loading the engine enough in 4th to demand max fueling. If all you got was 2900 rpm's then defueled you won't see 40 psi.

With the stock TC and 10k in tow mine would top 40 psi on every grade between Ontario and Pendelton. It would fuel all the way to redline at 3200 rpms and then boost would drop just under 40 psi. About 3100 rpms it would just tocuh 42 psi and hang there until the engine defueled.

Incidently the DP gauge had been pegged at 60 psi for a while and there wasn't any drop in boost. Every truck is a little different and they seem to react a bit different.

Yeah they are all different. . But I am pretty sure a 15K trailer and WOT in 4th from 1600-3200 would be loading the truck. . can't imagine it takes more the GCWR to get full fueling form the truck.

I get very apparent defueling from 2900-3200 then HUGE defueling at 3200. . which also mimmicks all the dyno sheets I have seen. . unless they have the 4,000 rpm tune.

 

[cerberusiam]

Yeah they are all different. . But I am pretty sure a 15K trailer and WOT in 4th from 1600-3200 would be loading the truck. . can't imagine it takes more the GCWR to get full fueling form the truck.

4th is not even 1:1 is it? Your still in gear reduction at that point, right?



Mine won't do it unless its in drive, TC locked, and a good grade. Only way to load it enough with enough rpm to max the fueling tables. Forget OD for maxing load. Hit the speed limiter before I ever got over 2900 rpms and just short of 40 psi.

 

[AH64ID]

4th is not even 1:1 is it? Your still in gear reduction at that point, right?



Mine won't do it unless its in drive, TC locked, and a good grade. Only way to load it enough with enough rpm to max the fueling tables. Forget OD for maxing load. Hit the speed limiter before I ever got over 2900 rpms and just short of 40 psi.

No its 1. 39:1... but its the gear I have seen the most boost in... but I never have to run it quite as hard in 5th because that usually too fast to be towing for the power demand

 

[RonSteele]

Same noise problem

My noise problem is exactly as described and started yesterday pulling my fifth wheel . Doesn't happen until 20 pounds of boost. I checked the plastic tank crimps and sure enough you guys were right on, the inner passenger side tabs that hold the cooler to the plastic tank have pulled back over about eight inches on the inner side of the cooler. Anybody else having this problem? Seems there should be alot more problems out there with this design. Anybody running an aftermarket cooler? and if so who's. How much did the stock cooler cost?

 

[AStewart]

Yea inside pass. side was where mine pulled apart. Im thinking of small claims court just to F with them. The new cooler is total diff. animal. The stock cooler list for $680. 00. I got mine for $530.