Engine/Transmission (1994 - 1998) Lost boost first month owned...now found after a month of troubleshooting....

[LPreddie]

I apologize in advance for this long post, but it was theraputic... ... ... ...



This post is to convey my high_Low-high as a new DC owner. How helpful this list has been. And to tell A few unique things I found during troubleshooting... ...



My friend (on his 3rd DC) convinced me to switch to a DC when I needed to sell my SRW F**D for a DRW. I am not partial to any brand; just need it to do its job (tow camper w/trailer). I bought the DC because of price and bombing potential. Honestly, I was not impressed with the stock power, my 95 Pstoke F**D felt like it had bigger biceps.



I started bombing with a goal in mind ( read TDR post for weeks). I even followed the recommeded order to be safe. gauges, filters, cat, kdp, plate, gsk.



Needless to say by the end of my first month of ownership I was beyond happy. With the new found power, I could not have asked for more.



Memorial wknd w/camper (heavy) we drove approx. 1000 miles in 4 days from E. Washington up and around the Olympic Peninsula and back. The truck drove nice, lots of winding roads, over mountins, and downshift to 3rd to easily pass RV's going below the speed limit (love that boost).



I don't know when it happend, but I slowly noticed with full throttle I could barely hold 45 on hills and I did'nt dare try to pass anyone ( or I was now the one in everyone's way). The next day it only got worst, i would pull over to let traffic by. I wondered if something broke or was it the elevation.



I will shorten this up some... ... ... ... ... ...



I hope I did not create a bad impression of DC truck as I found myself under the hood anytime we stopped for fuel or camp. I could not find anything (by the way piers used a special glue on the air bleed screw as it does not turn). I was so depressed... ...

It really took the Grin off my face on the way home. Once home I refused to drive it for anything as it was even more of a dog in town.



Toubleshooting... ... ... I checked for leaks reptd, even removed some lines. Bought plumbing to do pressure test. chk fuel filer chk cam plate if loose, chk gov lever, chk wastegate, overflow spring Nothing.



On my trip home the boost did return for about 2 minutes.

I spend late night reading post and eve's doing check again.



I remove the overflow valve and took it apart and stretched the spring to about twice its length ( I had already stretched w/no change). I drove 2 block and back and I had BOOST again. Whooohoo. I reconnect boost hose and no boost. Remove boost hose and still no boost. Ordered new overflow valve from piers (dealer 110 and Piers 55). Got part install no boost. Dang! Depressing. Start troubleshooting all over. Checkes all again R and R AFC and intake over and over.



TDR list exhausted, called piers, suggest lift pump (oh! that's what that does?). Ordered. Got and installed (it takes patience) no change. Dang! Depressed... .



Wife says, "you're going to have a new truck soon if you keep replacing parts with no change" That's just all I need on top of a one month old truck that can't get out its own way. Geeeessssseee.



Please don't let it be the injection pump..... Please... . Up til 3-4am studying post ; how the AFC works and its adjustments. Chk gov lever for the 6th time. It hits perfect and flush with bottom of plate although some on list suggest adj higher. Solenoid lift n hold test not work, troubleshoot but not sure. Gov lever does not move up full distance. Call piers, is there a height adj for lever? mine will not move all the way up plate. Piers explains, lever moves up with rpm of pump and engine speed, not by adjustment. But the lever is contacting as per the diagram. The wear marks on lever (not metal but oir residue) suggest the lever somehow has cycled under the plate.



Ok perform the gov lever adj ( at least I might learn something).

Set above bottom just incase it is somehow getting under plate.



Hot Dang!!!! Stella got her "boost" back. I was so happy, I almost forgot I was on a test drive, drove so far I almost couldn't find my way home (could'nt think clearly).



I am now back in business, just need to adj for excess smoke (starwheel as I did adj everything troubleshooting).



I hope there is something in here that may help others. It was very helpful and encouraging to see that many others have fought the low/lost boost problem for great lengths of time so maybe my post will encourage you to keep trying and not give up. In the process you will learn so much about how diesels operate it will build confidence to tackle future repairs yourself.



FWIW. I had to do all the work outside in sun on the rear lawn/grass as i have no garage, but I am building one.





Stella's new man... ... ...

 

[JoshPeters]

Congrats! There is nothing more frustrating than checking and rechecking yourself to find out you were right the first time. I had a smililar experience. Checked and found some problems, cracked intercooler, bad fuel return lines, but ended up finding another "hidden" problem. Critters in the fuel... alge... bad stuff dood. I would have never found it if I wouldn't have replaced the fuel lines.



Josh

 

[Vaughn MacKenzie]

Leon you sure went through a LOT for a new owner. Holy Schnikies!!! After convincing you to ditch the 4-letter friend I was feeling rather guilty for the grief you've endured the last 2+ weeks I wasn't much help either! Like I said on the phone you're the "expert" now, not me!!



I am happy to hear you got to the bottom of this. I think you're going to enjoy a lot of trouble-free miles for awhile and the next challenge that comes along will be easier to tackle.



I'm looking forward to going for a ride tomorrow. Let's lay down some smoke and turn Clearwater Avenue into Smokewater Boulevard!!!



Vaughn



PS Welcome to TDR by the way! Took me awhile to get ya on here but at least you're part of the diesel heads now

 

[Vaughn MacKenzie]

Well after Leon went tweaking on the AFC tonight to cut down some of the smoke, the power suddenly disappeared AGAIN



Any other ideas guys? The linkage on the fuel cutoff soleoid sort of came apart when Leon was messing with it, do you think that might have anything to do with it?



Vaughn

 

[Joe G.]

Has anyone looked at the waste gate?

Does it smoke a lot when the boost is low?

Has anyone checked out the throttle linkage?

Has anyone checked the AFC hose and connection?

Have the boots and intercooler been checked for leaks?



My advice is to find the problem before throwing any more parts at it.

 

[JBlackwell]

My truck is now doing the same exact thing. 3rd test run Monday night and that thing finally woke up and it was pouring the coals to it mister. I pulled one of those dissapearing acts. Got back in it yesterday and drove it again and the dang thing was doing what it did before.

Originally posted by Joe G.

Has anyone looked at the waste gate? YES. . check

Does it smoke a lot when the boost is low? NO smoke at all

Has anyone checked out the throttle linkage? YES

Has anyone checked the AFC hose and connection? NO

Have the boots and intercooler been checked for leaks? NO, it would smoke and not get boost if that was the problem



My advice is to find the problem before throwing any more parts at it.

What is happening to me is I am only getting 22-23# boost and NO smoke whatsoever when this happens. Monday, the boost went to 37# and it hauled butt.



I already put in a new overflow valve, checked the lever arm. . it looked like it was hitting right as far as I could tell.



Why would it run like crap one day, run like a scalded ape the next day, and then run like a dog again the next day???



HELP

JD

 

[Vaughn MacKenzie]

Originally posted by Joe G.

Has anyone looked at the waste gate?

Yes. Tested wastegate with compressed air, works great. Verified no leaks on wastegate control line from manifold.



Does it smoke a lot when the boost is low?

Not at all. Even with #10 plate all the way forward.



Has anyone checked out the throttle linkage?

Yes. Leon sat in the cab and floored the pedal and I verified it ran the full range.



Has anyone checked the AFC hose and connection?

Yes, tested for leaks, also verified air was blowing through it.



Have the boots and intercooler been checked for leaks?

Checked, tightened all clamps, no leaks found. Even checked air horn and intake plate gaskets.



My advice is to find the problem before throwing any more parts at it.

Joe, see answers to your questions above. . .



The problem doesn't lie anywhere with the boost, air leaks, etc. It is a lack of fuel. Leon has it figured out and he's back in business and I'll let him post an update. . .



Thanks for asking the questions though Joe



Vaughn

 

[LPreddie]

boost only sometimes --- check solenoid linkage.

If your boost returns sometimes when troubleshooting the problem may be a bad solenoid linkage. How to check. With key in run position lift plunger until coil hold, holds in full up position. Now try to pull down on end of solenoid rod. If the end rod move, you will need to purchase a new solenoid.

The best way to check is to remove solenoid from truck, cut tie wraps on boot, and try to separate rod from steel plunger. (it makes sense when you try it). The rod is held in the plunger with a steel c-clip and a ridge; if they are worn it no longer holds the rod strong enough.

Notice when doing the gov lever adj the solenoid needs to be in the full up position, well this creates the same problem. Remember that little arm behind the cam plate, it will not move out of the way. This limits fuel which limits boost.

It never made sense why I cold get 15-20lb but no more. This is what I found. I figured this had to be the problem when doing the bicycle inner-tube repair of the boot.



I hope this is helpful to someone.



P. S. I searched the TDR and did not find a post telling me these two pieces should be held together, I thought the boot was all that held it.

 

[willyslover]

good bird dog'in !!

 

[RJOL]

Originally posted by LPreddie

... TDR list exhausted, called piers, suggest lift pump (oh! that's what that does?). Ordered. Got and installed (it takes patience) no change. Dang! Depressed... .

Don't own a 1st Gen but from what I have read the mechanical lift pump is pretty much bullet proof. Kind of surprised that Piers recommended this for troubleshooting... That being said, he's the man!!!...