yes the inter-cooler is next to the radiator. I kinda doubt the intercooler is bad.. more likely the rubber boots that connect the tubes sometimes wear out. Just follow the tubes from the turbo compressor, check the clamps and hoses to make sure all is tight and there are no rips or tears.

I would also take your air filter housing off (the entire plastic assembly that mounts to the turbo), when that is off, give the turbo wheel a spin with your fingers, it should spin very free. if it doesn't, you may need a rebuild. This will also cause smoke.

If the starter is going out, this will NOT set any codes. It take the truck to Advance Auto Parts. I have had great luck and success with them. They can check your batteries, starter, and charging system for free in the parking lot.

Keep us posted!!

 

just ordered a set of gages boost and fuel pres. should have them by Friday. I have checked all the boots and found nothing leaking used soapy water. will keep looking..
thanks.

 

does the truck run fine? I am also wondering if you have a stuck injector..
I hate to say it but maybe try to find a set of stock injectors and install them. This will keep the smoke to a minimum...I know it sucks not having that extra power but this may be your only option if everything checks out good.
Did you order a Pyro gauge as well? adding more fuel=more heat. definitely want to keep an eye on exhaust temps! and ALWAYS install the thermo-coupler in the manifold, NOT in the down pipe after the turbo!

 

No, I only got the two. need to fix the smoke before I spend more money. Did get the new starter in, bet I am hopping the boost gauge will help with the repair. what boost presser should I be showing..?? been thinking about doing just that with the injectors what size would the stock one be 235hp.?


thanks

 

At work today i was pondering your situation.. yeah i got time! ha! Here is the conclusion i think:
your wastegate is opening letting the excess drive pressure out. get a boost elbow. they are super easy to install. You are not running enough boost to accommodate the larger injectors. Hence the smoke while towing.
http://www.ebay.com/itm/Edge-Products-Brass-Boost-Elbow-1994-2004-Dodge-Trucks-6000019-/121332326206?pt=Motors_Car_Truck_Parts_Accessories&hash=item1c3ff85f3e&vxp=mtrI have personally used the boost elbow from edge. It worked for me.

 

stock boost is around 20psi or so, when you are towing and you have your foot into it im thinking your wastegate is opening and only allowing 20psi.. the truck will sing at 30-35 psi.. I wouldnt go much higher than that for boost, if you do there is a possibility of blowing the head gasket.

 

I checked for that hose and elbow, I don't have one, I have a metal tube comes from the same place on the turbo to the wastegate. about 1/4" or so and 3" to 4 " long. but that don't mean that is not the issue. what you are saying sounds good. the elbow is a bigger line? so it will take more pressure to open the gate..??

 

been reading some other posts, I may have a turnbuckle, I have had this off once don't care to try it again. it never turned in fact it will not turn I tried thinking it would be easer to reinstall.so thinking about it, It will not turn so it don't matter.

 

Ok, got the boost gauge and got it installed, It is not reading zero it is at about 4lbs..
took the truck for a little drive, when I have my size 13 in in it will run up to 28lbs. of boost. So I figure I am running 24lbs at 80mph. when I let up it drops to 8 maybe 10 lbs. At 55 its showing 8 but remember it showing 4lbs before it start. at 70 not much change..
Is this sounding about right...???

thanks Mike

 

yeah sounding close.. wonder why its not reading 0? weird.
are you sure you dont have a wastegate elbow?
http://performancemachinemfg.com/i-8...set-turbo.html <-- copy and paste
it would be the blue hose, that part you are needing is the elbow that screws into the compressor.