Engine/Transmission (1994 - 1998) Freshly rebuilt 12V with mods, high EGT question

[FordCummins]

I recently finished the installation of a 96 12V 180hp motor into a 99 F350. The buildup of the motor included marine pistons matched to 370 injectors, 191DVs, #10 plate as recommended by Piers, 4k GS kit, 12mm head stud kit, fire ring'd block, ATS manifold, BD's super B turbo, 4" DP, BHAF and a 5" exhaust. With the plate in what I think is the stock position, and no modifications to the AFC, I think my EGTs are up too high too fast. Around town driving, it runs cool as can be, and with moderate accleration, or towing 9k, it stays right around 1000 or 1100 if I am acclerating. If I get stupid with the pedal, unloaded I can see 1400 with my foot right to the floor through the end of 4th gear. It feels like the truck wants to keep pulling like a bear, but I have to back out of it because of the EGTs. I can only achieve about 28lbs of boost at best, and was told the turbo is good for about 45psi. The timing is set at (I think, but I need to recheck) 16 degrees, and the truck is intercooled. Should I have more boost with this setup? Should I be seeing this high of an EGT that quickly with my setup? 4. 10 gears, in an 8100lbs truck. Thanks for the help guys, I have learned a TREMENDOUS amount from this forum. Sorry for the long post.

 

[tp0d]

Checked the wastegate? Mebe wana get a boost elbow, or just unhook and plug the wastegate for temporary to see what u get for boost. . 28lbs is low for that kinda setup methinks. .



good luck



-j

 

[FordCummins]

I pulled the wastegate hose off, and didnt see any change in the boost, which is why Im starting to scratch my head.

 

[Heepdriver]

Ck the timing and are those numbers pre turbo or post, with the ATS don't you have that pre turbo? If so you are going to see some higher numbers than those of us that talk in the post turbo temp range. I think I have seen on here where somebody said as much as 350 degrees. Do you have LOTS of black soot out the tail pipe? You could always try sliding the plate back a little.

 

[FordCummins]

That is preturbo. The smoke is there until the boost comes up, at which point, it almost instantly pushes 25psi of boost, and the smokes cleans up virtually 100%. I will call BD tomorrow and get their advice.

 

[98slushbox]

I would try checking your charge air system for leaks. If there is a leak you wont have the correct boost which in return causes more heat, but usually smokes more.

 

[thekidfan]

With some more boost temp will drop some but that is a lot of fuel for that small of a turbo, temps don't seem unreasonable to me!

 

[bmoeller]

How far forward is the plate? You should be over 40 PSI. I could hit 40 the plate in stock postion. I think I have a boost leak myself. Boost won't go over 35 right now, even with the plate full forward.



I can hit 1200* unloaded with my setup. I don't have my 191 DVs installed yet. Still needing to get a socket.

 

[Reb.B]

The super B turbo should be running at 40 psi at full throttle with that set up. I would definately pull out the 191's if the customer is towing. The BD super B is a great towing turbo. It will tow excellant with the 370's and marine pistons but its been my experience that when you mass the throttle the egt's are going to get up to 1500-1700 degrees, but the boost will be up too. To check boost, get a 4 inch hose and a 4 inch capped pipe with a air fitting. Hook up 35 psi of compressed air and listen for leaks. The 10 plate and gov springs that piers said is the best way to go. I'd really pull those 191's out though, they are instant heat.

 

[FordCummins]

Thanks for the replies guys. Reb. B, I think you got the impression that I am actually from the company FordCummins, I am not. I am just an average Joe who used their products and have a Ford with a Cummins in it now. I do tow with the truck, but not a whole lot, maybe 2-3 times a month, and no more than 10k, so that is not my ultimate concern, Id just lke to be able to run through 3rd and 4th gears hard without seeing 1400-1500 degrees. The problem isnt drastic, as I can control the temps very easily, while still pulling damn hard, it would just be nice to have a little more.....



I still have the stock DVs, would they be 181s since they were out of a 180hp motor? Is there a better choice for DVs then stock, but also better than 191s? Will I lose much power or see any downfalls from going to a different DV? I will check for boost leaks this weekend, and go from there. It sounds like you have some experience with this turbo. BD told me it was good for 42-45 psi, and will support 450hp. Thanks for the help so far, I really appreciate it.

 

[mikel]

Have you checked that the wastegate on your turbo isn't stuck partway open?



Mike

 

[Reb.B]

well, 450 hp is pushing it. 375-400 is more like it. It should be wastegated @40 psi. It will take 50 psi no problem, but the turbo really loses its effiency after 35-37 psi. If you want to smaoke people out and watch the heat rise then leave the 191's in. The 181's are nice and they dodn't bring the heat up as bad. There is no middle ground in DV's, just meaner ones and the 180 will have 181's in it from factory. If you want more power and less heat and a better burn at top in, then you need a go with the 215 hp pump. On the side of the pump the last three digits will be 887 or 913. Yours should be 911. The 180 pump is good, but is not as good as the 215 pump. They run the same cam, but the difference is the cut on the helix. Oh, you need to do a boost leak test before anything, with the timing and 370's the boost should be above 33 psi, ... more like 40 psi.

 

[FordCummins]

Im no expert by any means, but my understanding of increasing the size of the DV's allows the system to flow more fuel, so as to not be a bottleneck. The delivery valves do 2 things basically, they act as a check valve which helps make a sharp beginning and a sharp end of injection and they also keep some residual pressure in the lines so that the fuel doesnt have to compress as much to pressurize. All in all, it is there to minimize the ill effects of a pump and line system. Right??

 

[bmoeller]

Yep.



IIRC, Joe Donnelly told me he made 800hp on the stock 181DVs.

 

[FordCummins]

Its always the simple solutions... ... After pulling my boost gauge out from the A-pillar pod, and mashing the throttle again, I saw 38psi. Yep, a simple kinked boost line was causing my "low boost" situation. I have only driven around town so far, so I havent been able to really get on it hard enough to see a full boost condition, but so far Ive seen 37-38 psi. Thanks for the help guys, I learned more from this thread, which is all that counts.