Join Date: May 2009
Location: (518) on the boarder of MA+CT
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Oh i love this!!!!!!!!!!!!!! I will throw out the most common i run into on a daily basis. Also a worst case scenario (WCS) and tools involved.
Customer complaint-Lacks power, blows a puff of smoke upon hard acceleration. Check engine light is on.
Diagnosis-With IDS find EGR stop minimum code.
Repair- Remove the EGR valve, clean the port out with BG throttle body cleaner and a wire brush for a detriot injector, cycle the key on after all carbon or most is removed, you dont want this stuff igniting if you have the glow plugs on with the egr valve in! Throw in a new EGR valve BUT COAT the o rings with grease a light coating is sufficient.
Tools Involved-8mm socket and lady slipper pry bar.
Customer Complaint-Lacks Power Check engine light is on.
Diag-IDS pulls codes for P0299 or P2263 Remove down pipe and inspect for oil. If there is a heavy coating of oil in the down pipe, you have a failed turbo. Remove the turbo and inspect the housings for contact made by the turbine or impeller. If that isnt the case and there is NO oil in the down pipe, reconnect the down pipe. Remove the EBP sensor Inspect the tube If its full of carbon clean it out with throttle body cleaner and a pipe cleaner and with a smoke tester pump smoke through the EBP sensor tube. If you see smoke behind the engine its an up pipe. The other case is with IDS monitor EBP MAP and MGP along with VGT# commanded. If you can not build 23-26psi boost under full bore, you have possibly a clogged turbo and have to clean it. If you suspect a bad CAC Tube you can put soapy water on them and have someone boost the truck in reverse. If you see bubbles you have a leak. if you suspect a failed CAC you can pump smoke through it with the air filter inlet plugged off. If you see that the MAP sensor hose is cracked replace it, if you see the nipple on the intake for the MAP is plugged with carbon clean it. MAKE SURE the hose gets plugged in.
Repair-Up pipe replacement, Turbo cleaning, Turbo replacement MAP sensor Nipple cleaned map sensor hose replaced.
WCS- You have to do a CHRA. Another thing to check is the VGT solenoid Remove it, the end of the solenoid that pushes against the cam in the turbo if it looks like it has been ground down, or worn down. Also push against it with your thumb it should move smoothly should not bind.
Tools involved. If removing the turbo a couple extensions 10mm socket, 8mm socket to remove air cleaner inlet tubes, 10mm ratchet to remove the oil supply tube from the turbo. 7/16ths deep socket to get down and up pipe nuts from marmon clamps. to remove the VGT solenoid 12pt 8mm socket. Flat blade screw driver and small hammer to tap stuck and fussy clamps lose. 10mm socket and 13 mm to remove the up pipe bolts.
Customer Complaint-Engine sputters on cold start runs rough. No check engine light.
Diag-With IDS do cylinder contribution test with the engine cold. Run the injector interrupter what ever cylinder drops below threshold by 10-20 is a cylinder effected by an injector sticking mechanically.
Repair-Remove the valve cover(s) remove the injector(s) that are bad.
Tools involved T40 socket, T30 socket for oil rail there is a socket that is made by blue point that is 1/4 inch drive that will fit on the pass side bank 1 against the a/c box to get the bottom hold down bolts. 10 and 12mm semi deep swivel sockets and 8 inch and longer extensions you can get the valve cover bolts out without a fight. Air tools are great.