Engine/Transmission (1998.5 - 2002) Truck not running well

[S D Smith]

99 3500 DRW 24 valve 5 speed, My truck started having high RPM problems when accelerating. Over the period of a few days the problem has creeped down to where the engine wont go over 2000 RPM with huge clouds of blue smoke if I try. I suspected a turbo problem so I started by checking the wastegate with a coolant pressure tester that I modified, the pressure is incremented on the guage so I pushed it to 20 PSI and the wastegate didnt move. So I removed the actuator and finally got it to move but it doesnt seem to hold pressure above about 12 PSI. I then checked the wastegate arm, and I cant get it to move. Does the wastegate have strong spring on it or this frozen as well? The actuator rod was frozen tight to the wastegate arm so it seems as though this thing has been frozen for a long time. Also over the past few months I've slowly been losing MPG it's down to 17 from 21, I thought maybe the cold weather was the culprit here. The waste gate seems to be stuck in a closed position. Do these symptoms seem as though they could all be related to the wastegate or should I be looking at other things as well?

 

[RAJohnson]

Do you have any Idea as to your fuel pressure Any codes Could be a dieing VP

 

[S D Smith]

Havent checked FP, however I did recently replace the lift pump and it seems to be working properly. I've made several attempts to get codes with key on/off but cant seem to get any codes. So far the wastegate and actuator appear to be at fault hopefully not the VP at 83000 miles.

 

[RAJohnson]

Yep I think with your 99 you can not get codes with the key ON OFF thing. You can go to Auto Zone or something simular to that around you, and they may have a code reader to check for you.



You said you replaced the LP recently. How did you know it was bad? How long did you run with it being bad or ay least low on pressure.

 

[S D Smith]

I have a MAC Tools Enhanced scan tool unfortunately the software is outdated and only goes to 95. Someday hopefully soon I'm going to see if I can still upgrade it. I found that LP was bad when I changed the fuel filter and couldnt prime the system. I just bought the truck in July, and judging by the way truck ran after replacing the pump I would say the pump was bad when I bought it. The pump was replaced within a month of purchase. So far the truck has been nothing but a money pit, always something going wrong, but I really like the truck, and I'm determined to get through it.



So should I be able to operate the wastegate by hand easily with the actuator removed?



Since it appears that I'm going to have to replace the actuator and wastegate (probably wont know for certain until I remove the wastegate tomorrow) I've been looking for performance replacements. I havent had much luck on the wastegate itself, but I have found a performance actuator and line fitting. Are these worth it? or should I just go with OEM? Any suggestions?

 

[RAJohnson]

Boy I wish I could help you with your Turbo Questions, but I have no knowledge of them, at least any the would be reputable. I have a opinion FWIW on the turbo.



You asked (So should I be able to operate the wastegate by hand easily with the actuator removed) In my opinion NO. I think there is a strong spring on it. There are guys here that have a lot of experience with the turbo and hopefully they will chime in.



I think you should get the codes out of it, before you tear in to the turbo. Might save you a bunch of time and money. My guess and it is only a guess is a VP problem. Your statement on RPM in the first post, and your milage loss is what points me to the VP, yes cold weather will add to milage loss as well.

 

[ToolManTimTaylor]

engine wont go over 2000 RPM with huge clouds of blue smoke if I try.

May not be the wastegate ... . but the turbo itself. Are the visable areas of the fins coated in oil? If so I am willing to venture the center bushings are worn. Does the shaft wobble excessively? Any wear marks on the housing?



White I would say timing issue and VP DOA. Black ... Well it depends on who ya ask :-laf but blue usually = oil. oil can be the easiest when found at the turbo ... . hardest when the headbolts have to be cracked loose to take em out to look further.

 

[S D Smith]

I would have to look at the turbo again to verify for certain no oil, excess oil would've stood out so I dont think so. The the fan wasnt wobbly and spun freely. Would oil cause lack of ability to go beyond 2000 rpm? I havent driven the truck in about a week and one other thing just came to mind. As I approach 2000 rpm say around 1700-1800 the engine starts to sputter.

 

[ToolManTimTaylor]

If worn or bound up enough It could make it tough to get over 2k driving yes. Ahhh sputtering you say ... That unfortunatley sounds VP. Get the truck scanned for codes. It could even be an APPS issue you never know until all hard codes are pulled.

 

[S D Smith]

I just bought one of those code readers from the parts store and it said [no codes]. Thats kinda relieving hopefully its right. I also called the dealer for a price on the wastegate and wastegate actuator. They told me that in order to get the wastegate I would have to get the entire turbo assembly. The parts guy thought that I might be able to get the wastegate seperatly at the Cummins dealer so far I havent called them. Need some suggestions. Does anyone know if the wastegate can be purchased seperatly? If I have to buy the entire assembly I think I'll be looking aftermarket performance.

 

[DavidC]

Funny I did not read anthing about fuel filter. When they start plugging you get every color in the rainbow including blue. It is also probably the cheapest 1st thing to change and eliminate as a problem.



Dave

 

[DavidC]

To check on parts for your Cummins sign up here with your ESN.

http://quickserve.cummins.com/?SMIDENTITY=NO



99 Turbo parts

https://qsol2.cummins.com/qs2/porta.../qs2/parts/99/t/10.06/pp97476-04&header=false



Dave

 

[S D Smith]

Thanks DavidC, The fuel filter was just replaced at the last oil change, I'll check the links provided. I found on PDW sponser site a PDR HX35 modified turbo assy for 625. 00. I've called them but the person I needed to speak with wasnt there at the time so I'm waiting for a call back.

 

[S D Smith]

The turbo assembly is sitting on my garage floor now. The wastegate appears to have been frozen for a long time, I cant get it to budge even with torch heat on it. It is stuck in the closed position. Since the power loss problem just started I dont believe the wastegate is at fault. I wont be putting the junk part back in so now I have to wait to continue diagnostics