Archived Engine miss/black smoke

[JReinhart]

Crusing along today in my 1997 dodge, 5. 9 cummins, 5 spd, only mods are 4" exhaust, 35hp injectors, and Fliudampr. Injectors have approximately 250-300,000 miles on them. Truck has 1,240,000 miles. At time of problem was towing 27' 5th wheel trailer at 60-63mph, 6oo degree exhaust temp, 10psi boost. I noticed a vibration and saw I was blowing black smoke from exhaust. I went to 4th gear and reduced speed to 45mph. Exhaust temp rose to 850-900 (probe is on exhaust side of turbo). Reduced speed further to 35mph and down to 3rd gear, exhaust temp then dropped back to 650 range. Oil temp was normal, water temp was normal, oil pressure normal throughout the entire incident. I limped 3 miles to Sidney, NE where I shut down and inspected engine. I can start engine but it runs rough as if not hitting on all cylinders. As I have never experienced an injector failure in the 1,240,000 miles I have driven this vehicle I have no frame of reference that what I experienced was merely an injector failure or something more serious. I have no mechanical noise now when idling or during the failure, only the engine vibration, lack of power and black smoke. Any ideas?

 

[AKAMAC]

I think you nailed it with the bad injector diagnosis. Try using a laser thermometer at each ex. port to see temp differential.

 

[JReinhart]

I am going to try and have local Dodge Dealer here in Sidney confirm that I have indeed lost an injector. I will go ahead and buy 6 new DDP 35hp injectors and either have them installed by dodge or if too expensive put them in myself in the motel parking lot. I am only about 3 weeks from installing a brand new 5. 9 which could use the new injectors anyway. Appreciate the reply will hopefully know today if the diagnosis is correct. I just need the old gal to last those 3 more weeks and get the trailer I am now hauling delivered to the dealer. Shutdown out here on the road is not where I want to be. Thanks again and I'll post my results.

 

[JDiepstra]

If it turns out not to be an injector you may have a "boost leak". Do you have a turbo boost gauge? A boost leak woudl cause EGT to rise, and would also make it hard to burn all the fuel, giving you the black smoke. Check all air hoses and clamps for leaks. Good luck. And I am very impressed with your mileage!

 

[JReinhart]

After local shop in Sidney did some troubleshooting it appears there will be no more miles put on this engine. I ordered in new injectors from DDP and tried them in the #3&#4 cylinders with no difference in operation ie still dead missing on (2) not (1) cylinders. Mechanic says the pistons on these 2 cylinders are probably scorched. They had no way to test compression but their conclusion sounds plausible. I am trying to arrange a way to get the old gal towed back to Illinois and get a new engine installed. Thank you guys for the info but I don't think the old gal is salvageable.

 

[rkressg]

I am no expert on the 12v, but could it have been a P7100 failure? 1. 2mil miles is a lot of miles for an injection pump. I doubt it is a piston failure, unless it is burning a lot of oil, and you would hear it.

Is the turbo still producing boost? Could be a blown turbo or a blown boot?

 

[JDiepstra]

After local shop in Sidney did some troubleshooting it appears there will be no more miles put on this engine. I ordered in new injectors from DDP and tried them in the #3 cylinders with no difference in operation ie still dead missing on (2) not (1) cylinders. Mechanic says the pistons on these 2 cylinders are probably scorched. They had no way to test compression but their conclusion sounds plausible. I am trying to arrange a way to get the old gal towed back to Illinois and get a new engine installed. Thank you guys for the info but I don't think the old gal is salvageable.

No way man, you need more help before you give up. Post in the 2nd gen forum under Engine and Transmission and title it "Cummins with 1,200,000 miles needs help" and you will get a TON of replies. There are guys on here who know way way way way way more than I could have imagined. I'm serious. It will be worth it if you can save the 8 grand or whatever on the new engine!

 

[kenny61]

The only place I would tow it to is a diesel shop with the right tools to diagnose your problem. I would never guess about compression or cylnder / piston failure

 

[Missouri Mule]

I vote for the turbo going but I would have the injectors tested and a compression test done.

 

[EDankievitch]

Ok, Now here is something ya all might have missed. JReinhart said at the start of this that he saw black smoke (unburnt fuel) had a vibration (cyls not firing) and higher exaust temps(fuel burning out side of the cylinder). Any one have a thought? How about a broken exaust valve or two? Not broken enough to allow the stem to pop through and loose the keepers but enough loose the compression. I have seen exaust valves with chips and cracks in them. With 1,240,000 mileson that engine those valves have slamed closed many many times. I would bet that you could pull the head and find the cyls ok, well as ok as an enginge with 1,240,000 miles on it, put on a new head with good valves and I bet it will live to run another day.

 

[JDiepstra]

Any updates?