Cutting out once at operating temp

[dsldude]

I have had this issue for quite a while on my 04. It has a bucking and cut out issue above 2600 rpm going up hill. I have recently discovered it will only do this after it hits operating temp. When it does it i can back off the throttle and it's good. If i roll on the throttle soft it's not as bad. It runs like atop otherwise. Its driving me insane trying to figure it out.

I have replaced every sensor aside from cam pos sensor. New ecm. New injectors and tubes. Valves adjusted. Turbo fairly new. New water pump. New power steering pump. New hydroboost. New transmission. Filters all fresh many times over. Rail and lift pressures good. No diesel leaks. No boost leaks. Tried with a tuner and without. New prv. Cai is all clean as a whistle. Not losing oil or coolant. No diesel in oil. No blowby at all.

 

[TCDiesel]

You did all that and none of the sellers could help with what the problem is?

 

[dsldude]

Sellers? Nobody has a clue

 

[TCDiesel]

OK , Call Me.

 

[dsldude]

OK , Call Me.

You have a solution? Message me your number.

 

[TCDiesel]

Check signature, call today.

 

[dsldude]

Thanks to T and C diesel for helping me to isolate this issue. Unfortunately we are still at a loss. Another part of this is that it will only do this upwards of 23 psi boost. We also tried unplugging the fca and driving it. It sorta feels like it's in a mild limp mode when doing this. I am at the end of the line with this thing

 

[TCDiesel]

Just be patience. Try and use the CC buttons , turn on at above 40 MPH and hold the RES button and TH button on.

I still think it mechanical but try many different combinations to see if any thing changes.

 

[dsldude]

Any chance that head lift could cause these symptoms? I am seeing some coolant leaking from a head bolt near #1 cylinder. I wonder if the 2 things are related.

 

[TCDiesel]

Possibly, but I would check the coolant for exhaust gases, You can buy the test strips at just about any automotive store.

 

[dsldude]

Well after doing a test run with fca unplugged i have some issues. Now plugged back in, the truck smokes a bunch at idle, clatters a lot, and timing rattle is much worse. What happened? Am i seriously screwed here??

 

[TCDiesel]

No I tried to call You, no answer.

 

[dsldude]

Well, the head is off and all cyls and pistons are in perfect shape. That's a relief.

 

[TCDiesel]

Looks good, any signs of the HG leak?

 

[dsldude]

Maybe just at the front of the block where I suspected , but nothing near the pistons.

 

[dsldude]

Alright. Problem is gone. New head gasket. Smaller turbo ex housing. Went through all fuel lines completely. Had Xergy test injectors which they say are great and they did not charge me a dime. Battle won. Im not sure what was causing it, but it's finally gone. I am still getting some timing rattle at idle and certain rpm as well as a bit too much smoke when cold, but ill tackle that after I run it for a bit. Maybe a tune.

 

[TCDiesel]

The timing rattle is related to BMS nozzles, (Combustion knock its harmless at idle) just do OAs and adjust accordingly.

 

[dsldude]

The timing rattle is related to BMS nozzles, (Combustion knock its harmless at idle) just do OAs and adjust accordingly.

The excessive smoke and rattle at idle started up after running it with the fca unplugged. I replaced the fca. No change. The only other thing i can think it may have damaged would be the rail sensor. Thoughts?

 

[TCDiesel]

No the sensor is fine...unplugging the FCA should have no effect on Injectors operation other then increasing the combustion ( when unplugged) knock BC of the timing advance do to Max pressure. It does surprise me Exergy claim of great. generally its OGM these failed and its another $1K bill. Did they send Paper work showing the spec's and rates?

 

[dsldude]

No the sensor is fine...unplugging the FCA should have no effect on Injectors operation other then increasing the combustion ( when unplugged) knock BC of the timing advance do to Max pressure. It does surprise me Exergy claim of great. generally its OGM these failed and its another $1K bill. Did they send Paper work showing the spec's and rates?

Yes they did. They were all well within spec. I dont know what happened then Something happened immediately after the fca test. That's all i know.