Well CouncilBluffs is about as far away from me as you can get and still be in the same state so I cant be of any hands-on help.

I am leaning towards a boost leak somewhere. yours is doing exactly what mine did when I blew an intercooler boot.


Can you expand on this quote a little more. What did you have apart? did you have the turbo off? I am wondering if the wastegate is now stuck open or if something didn't get sealed properly when reassembled.

Check the intercooler boots again. (There is a 3" diameter tube that goes from the turbo to the intercooler. the two components are joined by rubber boots with band clamps. there is a matching one on the other side of the intercooler that goes from the intercooler to the intake horn that the oil-dipstick is bolted to.) When mine slipped off it was because I had removed the tube between the turbo and intercooler to access something else and everything was oily & slick when I reassembled it . It was not obviously unhooked, Just partially slipped out of one clamp, but that is enough to allow a lot of the boost created by the turbo to escape into the engine bay rather than being forced into the engine. Try loosening the clamps & removing the inter-cooler infeed & outlet tubes & boots. Cleaning them and the boots and inspect for any tears in the boots. then reinstall and see if that makes a difference. Since mine was oily it would reassemble fine and then slip past the clamp under boost. it wasn't fixed until I cleaned up the components so they were no longer oily & slippery.

I'm not trying to be condescending, but the constant smoke especially when towing screams boost leak to me.

Good luck man, and let us know how it goes.

 

I will give it a try, cant hurt, being it is the forth of July smoke bombs where easy to come by I did try pushing smoke thru the system did not find anything. and I installed a boost gauge it is telling Me, I am getting about 24lbs of boost.!
I will not be doing anything tell after the weekend. Going to the campground and tip a few. so everyone have a good and safe forth,

 

No, there is no smoke at Idle, only when I start out from a stop or step in to it or working it, (towing) or the like, it smokes all the time. when I am towing the RV the smoke is really bad inside the RV, black all the way down the side.
thanks
Mike

 

the other thing that I have seen manifest like a boost leak is a carboned up turbo. Soot, oil, & grime build up on the compressor fins and eventually the blades are doing nothing because there is no contour to grab the air. Its spinning, its just not moving any air. it takes forever to get up to speed and blows tons of smoke. I have never seen it on a Cummins truck but I have seen it on Cummins powered boats with lots of idle hours. That poor guy spent tons of money trying to find a problem, new VP44, new exhaust housing, new injectors, headwork with new valve springs and finally a new turbo. when pulling the old turbo off he saw the buildup. and had the old turbo gone through and cleaned up. The shop said that there was nothing wrong with his turbo other than the buildup. Reinstalled and *POOF*.... all fixed. The whole time we were telling him "boost problem" his marine mechanic was telling him that it was not that simple, it had to be fuel delivery &/or mechanical (weak valve springs).

I dont think that is your problem, but it is a possibility. My point is to start simple. when you hear hoofbeats it's usually horses not zebras. eliminate the simple stuff first.

also, you will still build boost with a small boost leak, the turbo will eventually overcome the loss, it will just take it a while to get there. you are only getting to 24lb of boost because I believe that is where the stock wastegate is set (somebody correct me if I'm wrong). The stock fueling curve in the brain-box says that at throttle position X we need Y amount of fuel because we are getting a known amount of air injected by the turbo. But if part of that air is not going through the engine due to a boost leak the result is a fuel heavy mixture without enough air to fully combust resulting in black smoke (unburnt fuel).

but you are correct.... it is the 4th of July tomorrow and nothing will/should get worked on until the BBQ's, Beer, Parades, & Hangovers subside. I have to drive my daughter in 2 parades tomorrow and one on Saturday and Sunday will be a day of recovery. Stay safe and I hope you aren't flooded out on your side of the state like we are here.

 

We came close to flood stage but picked and started to drop. My brother lives in Princeton IA. about 2 blocks off the river. He has sent pic. of the flooding..!! We both have had worse...

 

Up date, installed new injectors, no more smoke, But found my lift pump was bad so had to install a Raptor pump, not showing any codes so hopping the VP is not hurt. just need to get the fuel gauge from jumping. don't know if it is the sending unit or snubber . going to sale the old RV275 injectors for a $100.00 I think that is fair. Only 3 years old. thanks for all the help...!!!!

 

What injectors did you buy?

 

Factory RV 235s

 

RV235's are just stock injectors for these trucks correct?

 

that is what I am being told, and checking it out on the internet that is what you will find. If you are looking for some look back on this post.one of the guys found some on ebay, very cheep don't know if they have more but it is worth a look. I talked to the ebay person he was a good person and shipped fast. I think I had them in 3 days

I checked Ebay he has more listed $198.00 a set