Engine/Transmission (1994 - 1998) Help....Low Boost, High EGT, Black Smoke

[ablakemore]

Have a 1996 Calif. Dodge. Was about 300 miles away when I felt a slight miss, or hesitation. Was thinking fuel filter. Bought one then headed home. Normal WOT boost is about 19, and my EGT never gets over 1100. Had to slow to about 45 mph over the hills to keep my EGT under 1300. Would only go to about 8 lb boost at WOT then EGT's would climb fast with lots of black smoke. When I finally got home I changed the fuel filter. Didn't help. Today I pressurized the system from turbo to engine and had a leak in my EGR diaphram thingy. Just did't seem like enough to cause my probem. My question is how much does it have to leak? I would expect the turbo to put out a bunch of air but I don't know for sure. Also where should I go from here. Could it be the Waste gate? Fuel transfer pump?



Any help would be appreciated.

Thanks

Allen

 

[ramman]

First check the air filter a known culprit of smoke and low power,next I would suspect pump timing has slipped to the low side you may check the waste gate actuator for binding or frozen condition. I can't help on the egr system as I have never dealt with one. Good luck Ramman Tim

 

[illflem]

I would also say your pump timing slipped, especially if it came on real fast.

 

[SlyBones]

Another idea is to check for boost leaks.

 

[ablakemore]

According to my trusty Haynes book, it looks like the timing is a tricky job. Guess I'll be making a trip to the local Cummins shop.



Allen:{ :{

 

[illflem]

Allen, try to avoid Cummins or the dealer for adjusting the timing, they will only set it to factory specs by law. Your fuel economy and performance will be much better with the timing set to 15. 5-16°. There is peobably a performance diesel shop somewhere near you, the advantage to listing your location in your profile.

 

[Deezul1]

Double check for boost leaks. The boot down under the alternater can rub on the inner fender panel and get a hole in it.

good luck

 

[ablakemore]

illflem

Thanks, I think I will take your advice. Just need to find a shop now. I have always read the threads and very seldom post anything. I will update my profile. I live in the Sacramento, Ca. area.

Thanks

Allen

 

[ablakemore]

Deezul



I rigged up a plug for the turbo and pressurized to about 15 psi. I did have a few small leaks and one pretty good size one at the EGR thing. But I figure it would be have to be a really good size leak to effect my truck like its doing. But I really don't have a feel for how much air the turbo sends to the engine.



Allen

 

[Deezul1]

It sure sounds like a lack of air. Lotsa smoke= running way rich, high EGT= not enough air to cool it for the amount of fuel used. Check the air side of the turbo for impeller side play and make sure its not rubbing, some side play is acceptable as long as it doesnt rub, also remove the aircleaner from the box and see if there is any improvemt

 

[98rammer]

yeah, ever run with your wastegate hose disconnected and NOT plugged?

 

[drees1]

It does not take a super big air leak to cause performance problems as noted. I have seen intercoolers with cracks in the headers and loss of boost. ( On semi trucks) Fix that egr thing. Also, if your timing is stock, pin the engine with the timing pin behind the pump in the front housing, and pull the pin/plug thing on the side of the pump. If you can get the engine pin to work should only take 15 minutes to do a rough check on timing. The "blade" or pin on the pump should be centered in the hole. You will get a little oil out the hole in the pump when you pull the plug, be ready to catch it or clean it up. (about 1/2 quart. ) The Haynes manual shows it pretty well. good luck



Doug Rees

 

[ablakemore]

Today I plugged the EGR on the intake manifold. Still no help. Only get to 8 PSI boost with high EGT's. I checked the waste gate linkage and it seems to be OK. At least I could reach up from under the truck and move the linkage back and forth. Doesn't seem to be stuck. I will check out the Haynes book on the Timing and see if I can figure it out. First trouble I've had with my truck and it drives me crazy that I can't figure this out.

Thanks for the advice



Allen

 

[ablakemore]

Turbo?

Ok I just pressured up my turbo to engine again and could find no leaks. I can spin the turbo fins by hand. Can anyone tell me if the turbo can fail without any noise or it freezing up. Can I have a turbo problem? Symtoms are low boost, high EGT's. No hills in this area so black smoke is minimal.



Any help is appreciatedOo.



Thanks



Allen

 

[ablakemore]

low boost, high EGT's

Thanks to Brandon I removed my exhaust system and found that It was plugged behind the Cat Converter. Punched it out years ago but left some material in there and it worked its way out



Thanks for eveybody's help



Back on the road again



AllenOo. Oo.

 

[drees1]

Good Deal. At least nothing was broke



Doug Rees