How to add + 60HP safely/reliably?

[tjm]

Hello everyone

Hope someone can help answer some questions. I'm 5k miles away from 100K (1 year of drive time for me). I have a 60HP "tune" on my MM3 tuner. Creates a lot of black smoke when I accelerating or towing. actually puffs some black smoke at low boost (2-3psi). I have gone back to the stock ecm tune.

So air/fuel is rich. I'm assuming this is not good for the long term reliability for the engine ie carbon build-up. (I use diesel Kleen once a year at every oil change)

If I replace my stock injectors with BBI stage 1's wont that effectively make the fuel/air ratio rich as well? Dont I need to upgrade the turbo to deliver more air to the engine?

Truck is stock except for the MM3 tuner (running stock ECM) , a new BP manifold and the glacier diesel gdp2 pre fuel filter.

Thanks in advance

Tim

 

[AH64ID]

With a better tune you could run cleaner and add the 60ish hp. With BBI Stage 1's a 60hp tune should be very clean, depending on the tuner.

My BBI Stage 1's were super clean at less than stock power all the way up thru over 550 rwhp.

 

[tjm]

With a better tune you could run cleaner and add the 60ish hp. With BBI Stage 1's a 60hp tune should be very clean, depending on the tuner.

My BBI Stage 1's were super clean at less than stock power all the way up thru over 550 rwhp.

So is my understanding correct? - more fuel creates more exhaust, more exhaust creates more boost which creates more air. I can see this with the stock tune. With the stock tune just step on the pedal and you'll see smoke while the turbo spools up and then no smoke as boost is delivered. Did I get that right?

 

[AH64ID]

Yes, but there are other factors that effect smoke such as rail pressure, timing, and duration.

How much smoke do you get on your stock tune? I got none.

 

[tjm]

Yes, but there are other factors that effect smoke such as rail pressure, timing, and duration.

How much smoke do you get on your stock tune? I got none.

Not much and only for the period of time that boost is ramping. Hard to describe how much smoke. The MM# unit tells me i can generate peak 33 PSI so I dont think there any intake air leaks although i haven't performed an intake air leak test. I have the equipment just haven't done it.

 

[Cumminsboy77]

MM3 dosnt offer any tunes, enlighten me, is this correct?

I have the smarty touch which does offer the "box" smarty tunes.

 

[AH64ID]

MM3 dosnt offer any tunes, enlighten me, is this correct?

I have the smarty touch which does offer the "box" smarty tunes.

MM3 is custom tunes only.

 

[Ozymandias]

You still have a lot of smoke with the new Header?
I went from lots of smoke to almost non with a single header gasket leaking and repaired.
I'm running a Smarty JR in Tow setting.

 

[tjm]

You still have a lot of smoke with the new Header?
I went from lots of smoke to almost non with a single header gasket leaking and repaired.
I'm running a Smarty JR in Tow setting.

Well its hard to quantify what a lot of smoke is. Its all eyeballing it. But with a stock ecm tune there is smoke when i first stomp on the pedal, it doesnt last for very long. whereas if i use my 60hp tune if i stomp on it. its smoke all the time.

Im going to test the air intake system for leaks this weekend just to cross it off the list.

 

[tjm]

Well, was about to test my air intake system for leaks when i noticed this :

So I removed the hose from he output of the turbo and found this:

So the rebuild on the HE351CW that just occurred has to have a missing/blown seal. And of course I have a leak at the intake manifold bolts and gaskets which was easy to spot courtesy of the turbo.

I'll be talking to the rebuild shop first thing monday am of course.

Question for the experts? Is it safe to drive? I haven't noticed any smoke on the stock tune.
I'll also be removing all the air intake plumbing and cleaning out the insides. How would one go about cleaning the intercooler?

Tim


Just when you need your truck...

 

[tjm]

This video which is pretty helpful

So drain? No kinks, just like original.

Back of compressor housing

Excessive crank pressure? I'll find out tomorrow.

 

[CVR222NV]

Any thoughts on gapless turbo seals? Not going to deal with an excessive crank pressure.

 

[tjm]

@CVR222NV - I think your saying the same thing that was stated in the YouTube video I posted. Turbo seals are not designed to withstand excessive crank pressure. That video I posted is just a generic "how do turbo oil failures occur", not sure its the same for the HE351CW. Regardless of what seals I have I don't think I have excessive crank pressure. I removed the crank case breather and blew into it. No back pressure from my lungs and I could hear the air escaping through the vents. Breather tubes are not bent. the breather tube that hangs above the ground is not plugged. I started the engine up with the crankcase vent on sort of finger tight, but sealed. The breather wasn't moving around no gasses were escaping around the seal. Also the breather is about 1 yr old. Just replaced it.

I also removed the drain tube to the turbo - no plugs there.

That leaves the turbo if my diagnosis is correct.

When I first installed the turbo. I heard a loud screech the first time I turned it over. For about 1/2 second. (sound like a belt screech). I did pre-lube the turbo with 2 oz of fresh oil while spinning the impeller. Wondering if something wasn't installed right or they used crappy components when they rebuilt it.

Sort of out of ideas short of pulling the turbo and taking it to the rebuild shop Monday am.

Would really like to use the truck to pick up a 1-ton mini excavator tomorrow. Does anyone think I'm on thin ice driving about ten miles to the Home depot and back?

Thanks All

Tim

 

[Ozymandias]

I'd say bad turbo from the start from what you say.
And as it is a fresh rebuild you have a warranty on it, right?

 

[tjm]

yeah rebuild was on dec 9th Ozy

 

[tjm]

Pulled the EM and Turbo. Oil only leaking out the compressor side.

 

[sag2]

I'll also be removing all the air intake plumbing and cleaning out the insides. How would one go about cleaning the intercooler?

Tim


Just when you need your truck...

Remove the intercooler and wash with dish soap and water until it comes clean.

 

[tjm]

Remove the intercooler and wash with dish soap and water until it comes clean.

Thanks Sag2

 

[tjm]

Well turbo shop says turbos fine. Going to go pick it up.

 

[CoastyAV8R]

Did they have any insight on where the oil is coming from?