penny for your thoughts

[Shane Farmer]

Hello fellow cummins brethren, I'll start with the obvious, this is one cool website!! And with that said, I am needing to know would the manifold and and wastegated turbo off a 2nd' gen ctd work on my first Gen. And what would the benifits of this change be? My reason for doing this is my cummins only shows 5# of boost. I thought this might be the key... and I found the whole setup for 200$ is this a reasonable price???

Id be very thankfull for any input







92' w250 converted dually, club cab, 184k,5 speed getrag, pump tweaked 30%, bd turbo and pyro, and one proud owner Oo.

 

[matches]

Back up a second, First you must find out why your boost #'s are so low. Blocked air filter, bad intercooler or boots, little to no fuel??? The BD turbo should be pumping some serious air with your pump mods, I'm guessing you should see close to 20 psi or more. The second gen stuff won't help you if your problem is with something else. Back to your original question, is it off of a 12 or 24v'er? Then you would have to check if the manifold is good or has it been shrunk and cracked, if it would fit at all.

 

[paccool]

The 24 valve manifolds have round exhaust ports while the 12 valve engines have rectangular ports. I'm not sure if ALL 12 valves are rectangular or if some of the later years had the round as well. Hey Bushwacker, do you know?

 

[BushWakr - RIP]

If you're only getting 5psi then you've definitely got some issue's... . they should not be hard to find either...

First, pull off all the intercooler boots... . go over them up close and personal... roll them between your fingers like rolling a cigarette... look for cuts, 'rub through' etc... also look for signs of dry cracking like a tire get when left sitting in the sun unused for years.

Next, if all the boots are good and all your clamps were tight reinstall the boots, tighten them really well and pressure test the intercooler.

You'll need a piece of heavy rubber hose the same diameter as the turbo air intake. Slide that over the turbo inlet and, on the other end you'll need a plug/cap. This cap should have an air fitting and a small gauge.

Pressurize the system with no more than about 20psi and go looking/listening for leaks. It is normal to have some slow leakdown... all the valves in the cylinder head are not closed at the same time so some leakdown is normal but you should not have a noticably fast/consistent drop in psi.

If you do, you've got an intercooler leak(s).



As for the turbo itself, it is at fault I'm pretty darn sure you'd hear/feel/sense that issue very clearly. It can be checked by pulling the air inlet from the front of the turbo and, grasping the nut on the shaft end then moving it side to side, then, front to back.

There is a very modest amount of side to side that is acceptable but not enough to allow contact with the inside of the turbo housing wall. If it make contact then the turbo is on the very failing which is usually a very unpleasant experience.

Look for signs of contact. When you do the test fire up the truck for a few minutes and let the turbo bearings get well lubed, then shut down and do the check.

As for 'front to back' movement, there should be NONE !! If there is, you need to tear it down (or have it done) and install a new turbo "cartridge" or, rebuild kit.

Even a stock 1st gen turbo should be able to produce will into the mid/high 20 psi range when you have enough fueling so look for turbo/IC boot/IC core pressure loss.



After that, you can go on to more testing if needed but I think you'll find your problem fairly quickly.

If you have any guages maybe you could provide some info on your EGT's, smoke levels etc... that will also help the guys get you on track.



pb...

 

[tugboatphil]

Can't Add Any More Than That...

Check for leaks. That said, if you went to wastegated turbo from an early 2nd Gen, you be decreasing the size of your exhaust housing. Your 92 has (I think) an 18. 5cm housing and I think the WG ones were 12cm. You'd get a quicker spool up, but would have to watch and adjust for higher exhaust temps, especially under load.



Good luck, and if I didn't already say it, Welcome Aboard!

 

[Shane Farmer]

thanks

Hey guys,

thanks very much for the insight. Ill check my intercooler for leaks and with a little luck I'll be pushing 20# of boost pressure in no time. I appreciate everyones addvice and (if you're like me) it takes 10 minutes to write a reply

so thanks for the time spent. Every body have a good evening



92' w250 club cab, converted dually 4x4, 5 speed getrag,184k,pump tweaked 30%, bd turbo and pyro gagues, and of coarse one very proud owner