Rolling to much smoke
 

Hi all, My name is Mike. I drive a 2001 24v Cummins. I am a newbe to the sight.
I am having an issue with to much smoke, the motor had a fresh rebuild a copple years back, at that time I went 50 over on the injectors, ( save on fuel and little more power) and it is doing great.
when I am towing the fifthwheel the smoke is making a mess of it, and it gets inside it.
I don't want to give up my power and fuel saveings but we need to stop the smoke somehow. buying a new 2015 rv and cant have the smoke any Ideas would help...:scare2:

thanks Mike

Do you have any sort of tuner on the truck? If so what level? And most people I know who want to keep the power and tow usually get a turn-down exhaust tip to keep it off the trailer. Just a thought!

I don't have a tuner, been thinking about one but don't know much about them or weather it would do much for the smoke? turning the tip down is something I had planed to do. If I go with a tuner witch one should I go with..?? and would I be able to change the air flow. I am thinking it is a lack of air, or how would it work.

thanks Mike

How does your air filter look? And has anything boost wise been tampered with, like does the truck feel like normal power? If you plan on getting a tuner, its really what you want it to do. But there are plenty of options for our trucks. I have an edge comp box and love it, but with that you need a bigger fuel pump to keep good fuel pressure to the motor.

I am very anal about keeping filters clean, I don't think anything has been tampered with everything is stock but the injectors, I am going to start looking at tuners, I don't think I need to use more fuel. LOL where would be a good place to look for tuners..??

any box that will do timing will get you more efficiency. Whose injectors are you running? That can also make a big difference.

A tunnel ram intake plenum will also reduce some smoke.

Found a leak at the back of the Turbocharger where it connects to the exhaust. don't know if that would make smoke or not, trying to find anyone that has seen this before.

I really don't remember what Injectors I used. I talked to the mechanic that did the rebuild he is thinking they where RV,s and they could be the problem. but he don't know about the leak at the back of the turbo, I took it apart cleaned it put it back on to see if there was something not letting it seal.???

I don't think the leak on the back of the turbo is your issue.
The RV injectors are the Bosch RV275's they are good for 40-60 hp more.
I would look for Boot leaks from the inter-cooler.
also a nice chip is the Edge EZ, this only adds fuel injection timing, not more fuel, that may help with some smoke. The edge EZ also comes with a boost elbow that mounts to the bottom side of your turbo compressor to the waste-gate. This will allow you to build more boost and help with the smoke.

You can also try getting the RPM's up higher.. you may be lugging your truck down too low in the RPM's that will cause excess smoke. Of course you can always just ease into the throttle too.

Do you have any aftermarket gauges installed on the truck? adding any more power other than an air filter, you really want to keep an eye on what is happening with your engine. You also may want to upgrade your stock fuel lift pump. the stock lift pumps are weak and can handle about stock power levels.. adding any more fuel (like bigger injectors) will tax the stock lift pump, starve your VP44 inj. pump and then you are dead in the water.. bad deal and an expensive fix.

We are here for ya bro!! :)

when I am towing or under load it is smoking all the time. I don't know what the inter-cooler is. it set behind the radiador ..?? and with this going on the starter give up on me. oo and I checked for codes none.

read up on the intercooler, I think I may have to check futher in to this. thinking about taking it off the truck and checking it. or find a way to push smoke in it to see leaks

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!!:tu:

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. :humm:
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! :c:

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. :c::c:
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.:argh:

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.

I was looking into it. with auto trans. they used a hard line?? I look up what you are talking about, I can see where it would be, but it is taped on the side of that for the hard line. I am thanking I only have one move left, go back to factory injectors. do you know what that would be..??

thanks mike

http://www.ebay.com/itm/FUEL-INJECTORS-6-NEW-BOSCH-Turbo-DIESEL-DODGE-235-HP-5-9-CUMMINS-98-1-2-2002-/231244130467?pt=Motors_Car_Truck_Parts_Accessories&fits=Year%3A2001%7CMake%3ADodge&hash=item35d73968a3&vxp=mtr
these are stock. you can try to find a set of used ones for less but this price is pretty darn good.

also i did some research and your truck has the HY35 turbo not the HX35 like my old one.
you can also check out a boost fooler
BD Power - Product: Electronic Boost Builders

YES, that is a good price think I am going to order them, would they work with the boost builder.? or would I be going backwords. (235 and boost builder) anyway I want to thank you for staying with me and helping. I am not to smart when it comes to working on cars and trucks. if you was here I would be happy to buy a beer or two or what ever you would like to have..!!!

thanks Mike

You need to get it to a good diesel mechanic before you just start throwing money at it.

I just can't understand how rv275's and 28psi is blowing to much smoke... There has got to be something missing here

I am thinking it has to be a stuck Injector, there is not much it can be. I have pumped smoke in the system and found no leaks...

deffinetly keep us updated!

Where are you at in Iowa?

Council Bluffs,

Does it smoke at idle?

To see if you have an injector(s) out, you can use a temp gun and point it at the exhaust manifold and see if one or more cylinders are hotter then the others. If you do find high fluctuation in temps, then the one reading high is your issue.

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,:c:

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. :usa::usa::usa:

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.:jump: 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