Engine/Transmission (1998.5 - 2002) smoke problem

[pgleavitt]

The last 2 performance upgrades that I have done both produced too much smoke. I'm talking about heavy black freight train like smoke. The first upgrade was a Catcher ECM that worked well but the smoke was way too much and I pulled it out. The second is a set of Don M's 1. 5 injectors and I have the same problem. Something is wrong with my truck. I have good turbo pressure at up to 38Lbs. and seems like excessive EGT's. The smoke clears up at about 20 psi boost but until then it's pretty bad. The engine doesn't burn any oil between changes. I have unhooked the pump wire from the Banks box and It made no difference in the smoke level. I run a constant 12psi fuel pressure at cruise with a Fass. The problem exists at sea level and altitude alike. No codes and idles smooth. Any help is greatly appreciated.

 

[NUTNDUN]

So you have an edge(which I am guessing is a comp if it has a pump wire tap with it), you had the catcher ecm, and 1. 5 edms, it's no wonder the thing smokes. Do you have an upgraded turbo? Possibly an intercooler boot is leaking but doesn't sound like it. I think you have too much with not enough good boost if you are on the stock turbo, 38 psi is pushing it(at least I think) What about air intake or exhaust(I don't know what the banks powerpack comes with)

 

[Stamey]

Sounds to me like your boost isn't coming up quickly enough. As Nutndun suggested, perhaps a boost leak is causing this. You might get 38 psi eventually, but I'm betting when the smoke is occurring you have little or no boost. Any idea what size exhaust housing is on that turbo?

Look for a leak first.



Chirs

 

[pgleavitt]

The Banks system taps the pump wire also. It comes with a bigger exaust housing on the turbo and a different wastgate setup. Will have to check for a leak. I have the Piers boot upgrade.

 

[NUTNDUN]

The Banks system taps the pump wire also. It comes with a bigger exaust housing on the turbo and a different wastgate setup. Will have to check for a leak. I have the Piers boot upgrade.

Does it smoke alot just normal driving or is it only when you romp on it? Your injectors are bigger then my 275's but even with the tst on setting 9 in 4th gear all I can get is a small puff of black out, at night it looks like it takes out the intersection but that is just the haze LOL. I get about 38 lbs when on setting 9 too and it is definately the limit of the turbo because my egts sky rocket quickly. I would check all the intercooler boots, check for any leaks in the intercooler itself(old trick to doing this is taking ether and lightly spraying it on the intercooler with the engine idling, normally it sucks it in and the engine rpm increases but depending where it may be leaking it may have pressure and never pick up the ether).

Do you have an air intake or BHAF?

 

[NUTNDUN]

I forgot to mention too that I seen someone else say about the map sensor in another thread, if that is whacky it will make the truck smoke like a freight train.

 

[pgleavitt]

OK so today went to Home Depot and picked up the parts to build a boost leak tester. Hooked it up to the rubber intake that the filter is connected to the turbo. With 10lbs of air pressure found a leak in the intercooler. Can they be repaired or is it time to upgrade to a better unit? Also with just 10lbs of air pressure the rubber tube to the turbo expanded alot and I was affraid that it would let go. How could you ever get 20lbs like some of the other threads I have read?

 

[Stamey]

The rubber is flexible. I'm not saying it will last forever, but it will last a while. I can only imagine what my rubber boots look like when I am pushign 5 psi of boost. Perhaps a baloon? I have blown one, on my cold pipe between turbos. It was a reducer though, and subject to more expansion/contraction due to where it was located. I replaced with silicone now and I think that will hold up better.



How did you build the boost leak detector? I have heard of this before, but never seen instructions or the actual detector.



Chris

 

[pgleavitt]

Took the rubber connector tube to home depot and found a black abs plastic fitting that was 4" dia. on the outside and on the other end it had internal threads for a 4" cap. I think it is used as a sewer drain clean out. Went to Big O tire and they gave me a metal valve stem that had rubber gasket and nut. Used sealent on the fitting and cap and drilled a hole in the cap for the valve stem. the hole setup cost me about $10. It worked well and I could monitor the air pressure at my boost gauge while my buddy put the air to it. With the pressure at 10psi I could hear a leak in the intercooler on the passenger side bottom area.

 

[Stamey]

OK, thanks.



Chris

 

[Jermey1980]

when my map sesor went out it would build any boost and not smoke much at all