Really High EGT's, any suggestions?

[Powder Extreme]

Hi all, I'm having a problem with really high egt's and I'm hoping somebody has some ideas. My truck is an ETH (I know that's most of the problem ) anyway, I have DDII's, a PE Comp, DD 4" exhaust, a 16cm housing, and a custome airbox that breathes the same as the Pyscotty. At full throttle I see 30-32psi of boost, with the Comp on setting 1,1, (the lowest) at a constant speed of around 60 with the egt's between 550 and 600, I can give it full throttle for about 5 seconds (reaching 90-95mph) when I back out of with the egt's between 1400-1450 (Spa gauges) That's running empty with no wind, put a load in it and things are much worse. Cruising empty around 75 my egt's run right around 800, does that seem kinda high? Any insight would greatly help, what fun is all this power if ya can't use it?

 

[Steve G]

Power Ext. , when I'm running at 70-75 I'm between 700-800 also. I think that's pretty much normal. A mechanic I know at Cummins told me not to worry about it that he also thought that was normal. With the heat we are having, I can easily push 1100+ when going up a small hill empty. I would be concerned about the 1400-1450 your having, but other than that, I think you'll be alright.



Steve

 

[Cryppie]

Powder, what altitude are you at? The higher you go, the higher your EGT's will go at WOT. Just FYI.

 

[Powder Extreme]

Cryppie, I am at a fairly high altitude, 4500-5000 but I travel quite abit, Arizona, Florida etc. It is slightly lower near sea level but I can still blast right on past 1450 egt within a short period of time.

 

[daveg]

Powder Ext. I am running about the same set-up as you with the exception of DDlll's and a HX40/16. My egts were high until I installed the HX40. I haul a 16' Marlin I/O with 4. 3 and tow a 30' travel trailer. My gross weight is 19,600 lbs. With the PE Comp on level 1, I can pull a long 6% grade at 60 mph in 5th gear running 28 psi boost and about 1100 F pre turbo. Egts will still exceed 1200 F at WOT (35 psi) but haven't found a hill yet where that kind of power was needed.



Running empty on level 5 at WOT I am pulling 40 psi and can get the egts to 1350 F but am well over 100 mph at that point.



The HX40 made all the difference, love the set-up. The PE Comp allows you to have the ultimate tow level and the higher levels to create the adrenaline rush.

 

[work2muchplay2little]

P. E. , give us a little history of your EGT's as you BOMBed your engine, especially what were they before you added whatever you added last?



I think I'd agree that the thing you need is more air/boost. Check everything that may be hindering this; air filter, intercooler connect hoses, bug-crudded intercooler fins, intake manifold gasket, turbo waste gate, and might as well clean your IAT if not already done.

 

[Powder Extreme]

Okay, more info: When I was at the 275 injector, open 3" Boost elbow and module, K&N level, I didn't have pre turbo pyro setup, but post turbo would easily reach 800, sometimes 900. I know now since I had pre and post pyro's for a while that 900 post is in the 1500 pre neighborhood. I then went to the Banks Power Pack setup, which the ottomind would limit the temps to 1350 then defuel. The truck would hit that very quickly post temps would never go over 800. So I would say that even since the 275's and boost elbow (ran 28psi) the truck has had the high egt problem. With the Banks setup I had 4" exhaust, Psycotty style airbox and 275's. Banks told be to disable the wastegate to see if more air would help, at that time I would run around 37psi. I added an EZ to the setup which seemed to be my best overall, boost would max out at 41(I'm wishing I still had the Banks stuff actually) At that time the truck ran really well,(370hp, 915tq) got 20mpg and would take considerably longer to hit the 1350 defueling mark. I only ran that way for a short time when Edge offered me a Comp Box, I went down there and had DDII's and a 16cm housing installed as well, since then I've never been able to get over 34psi boost. I've checked all the intercooler lines, no leaks as far as I can tell. Every since going to that setup I've never been able to use full throttle for more than a few seconds. I removed the Comp and installed the EZ, same problem but would take slightly longer to hit 1450 (not much). I've pulled my IAT sensor, not dirty at all, and using the resistance values I've seen posted here in comparison, the sensor seems to be okay.



I've been thinking of going to an HX40 but people I've talked to with them say they suck for towing with a manual trans. Way too much lag is what I'm told. I'm not all that happy with the lag the 16cm housing gave me, I sure don't want it worse.



Thanks for the input, you guys are great!!!

 

[work2muchplay2little]

Have you tried stacking the EZ and Comp Box (MAP sensor -> Comp -> EZ -> wiring harness to ECM) and setting the EZ on jumper 1 (timing advance only)? Do you still have the boost elbow in to delay wastegate opening? It sounds like you've got a fueling/boost mismatch - too much fueling for the boost available. Need to either increase your boost at current fueling levels or slightly decrease the fueling at the lower boost levels.

I agree that an HX-40 and towing with a manual would not be a great combo. Great high RPM performance but at the lower rpms, you'd smoke a lot everytime you tried to build up some boost to accelerate or climb a hill. Piers' new HX-35 sounds like it would fit your needs well, might want to give him a call http://www.piersdiesel.com.

 

[Powder Extreme]

You can't stack the Comp box and the EZ, according to Edge, the reason being the data link plug, both the Comp and the EZ need to plug into the data link, no way of stacking those plugs. I haven't had the boost elbow for a long time. The Banks unit replaced the housing and wastegate, the new 16cm housing is a non-wastegated type. I've been considering putting my old Banks housing back on, but bigger housing = lower temps right? The Banks is a 14cm housing, but the lag was much less, so it would get more air in quicker, probably worth trying. According to Edge the Comp box on setting 1,1 is basically a copy of the EZ box, so it really isn't much fueling. If I set the box on level 3, or worse yet level 5, the egt's hit 1500 almost as fast as I can push the go pedal. The truck will actually accelerate to a faster overall speed at the lowest setting. I'm wondering if I might have a different problem with the truck since it seems to have always ran hot. I see lots of guys with mods like mine or even more radical, and they don't seem to have the egt problem I do..... I'd love to buy Pier's new turbo, but don't have the extra cash right now, and I'd like to talk to a few more people about it first.



Thanks again

 

[Briar Hopper]

I have an Hx40, and a TST PowerMax 3 Competition, DD3 injectors, and a Van Aaken, and I tow my travel trailer (6000lbs) with my PM3 set on level 5 (level 6 is the highest "safe" level to use) so I'm here to say it CAN be done, and with a load I don't worry about turbo lag, it's not there...

The lag is there, however, when trying to drag race, I don't have enough boost down low, quickly enough... .

I can do about 70-80mph uphill on a long grade, and only see 1100-1200 EGT pre-turbo, while towing. The truck has also done fine while towing a Bobcat on it's trailer, rough guess says that was a lot more weight than my RV trailer !!!!

 

[CUMINNTSTRKN]

powder



i just installed a hx 40 from smokindiesel.com and i love it. i too could hit in the 1700 pre egt's with my comp box but now i can't get it over 1400. as far as towing i drove from helena to shelby yesterday towing with a gcvw of 24k-25k. i pulled everything in high gear except the north hill coming out of helena. i was in 5th at 65mph. i agree there is alot of lag while drag racing but when towing the boost is already up so i don't see any lag.



jim

 

[Powder Extreme]

How ya doin Jim? I was wondering if you had gotten your Comp box yet, have ya had it on the dyno? I'm not looking to make a drag racer out of my truck, but what about the lag in between shifts? Isn't it pretty bad? I remember you telling me about the lag your buddy's truck had.



Jerry

 

[Evan A. Beck]

Jerry, you are running really hot...



I have the DD3's (original batch) and an EZ end rarely ever get above 1300°... And I still have the stock 12cm² housing. Also, I have a PSA and 4" straight exhaust... Before the EZ, I dynoed at 350/800... Who knows where I'm at now...



Defiantely sounds like you may be low on boost, so check for boost leaks... At high boost, you can really get a rise in EGT with just a small leak.



May want to try the 14cm² housing just for comparison, and see what happens.



I hate to say this, but I think you have entered the land of the HX40. Lag won't be that bad, just adjust the Comp box accordingly--have the fuel come up faster to eliminate lag. Be sure to get one of DD's HX40s, as far as I know, he hasn't had a failure yet with any that have been sold.



Might also be time for water injection...



BTW, I had no idea you were from Montana... Never noticed that before. Closer than I thought!

 

[Archive]

Here is a thread on a DD HX40 failure... the cause and customer service is yet to be determined...



HX40 Failure

 

[Evan A. Beck]

First one I have heard of...

That's the first DD HX40 I have heard of that has failed... I know the ones from Majestic had a really bad failure rate. Also, you may want to check out Piers' new modified HX35. I think that is the route I am going to take.

 

[Archive]

I remember a thread about DD hx40s and how they welded the wastegate, I don't remember if it included failures... could probably search and find it, tho.

 

[Fred Swanson]

Powder, your best bet would be to try different combinations. Try the 14cm wastegated housing instead of the 16 non.

Try running without the Comp Box.



My setup is very similar to yours, yet the Hot PE produces more power. I could get the EGT's up to 1500 fast. I have had lower EGT's with the modified HX-35 and a 12cm housing. I am shortly going to try the 14cm housing, to see if it can get lower. It should. With the 16cm not being wastegated, I believe you may be past the efficiency of the 35 and generating heat with the high boost. Ask Piers, the efficiency of the 35 isn't at 40 psi+, but lower around 34-36 psi. Any higher, and no wastegate, and you're probably not helping your EGT's.



I can still hit 1500, but that's at about 80-90 MPH on level Hot#3. And that's in 100 degree heat in the desert. While at Timberline and (DTT)Canada last week, it took even longer. Heck I bet I gained 25 HP just being there. The air was much denser.

I've heard it stated here before, take parts off until you find the culprit. In other words, experiment a little more.

E-mail or call me if you want to talk about it in more depth.

 

[Powder Extreme]

I'm planning on buying the new turbo Pier's is building when I have the cash. But I also want to wait a while to make sure it will hold up. I've heard too many horror stories about the HX-40



Evan, when you say 4" straight exhaust what exactly do you have? No muffler or resonater? where does the tailpipe exit? I ran 4" open in front of the rear tires for a while, way loud, which was okay, but had a really bad drone at 65-75, which wasn't okay.



Jerry

 

[Evan A. Beck]

4" stainless straightpipe, standard exit (aft of the wheels).



Piers' new turbo is pretty tough, and I have only heard of (and seen) one fail... I plan on upgrading to one soon... Just can't decide on the housing though...

 

[dasyure]

HX-40

Had my hx-40 with the majestic tweaks since january with NO problems, egt will hit 1500 at wot in about 5 sec I just figured I needed better intercooling and some fresh air just been busy and drive cafully untill get time to mess with it

Sean