02 7.3L smoking, no power, no boost but high EGTs

[ProGunProgressive]

So a few days ago the 7.3 starts sputtering under load, going up hills, etc. Boost is about 17-19lbs typically, and it'll spike up to that amount, but then after a few seconds drop to 13-15. So, trying basics first, I change the fuel filter, but it wasn't really all that bad. The filter bowl looks fairly decent.

Problem only gets worse...sometimes white smoke when I goose the throttle, sometimes black smoke.

For the first 20 mins of driving, it'll be ok, but it'll get worse and worse until eventually I can't make more than 45mph...sputtering becomes pretty intense. Stop and let it cool for a few minutes and I'm back on my way...repeat this process several times. One thing I notice is that even though I'm only making about 5lbs of boost when it's really falling on its face, my EGTs are through the roof...1200-1400* even though I'm not making any power or boost.

I tried cleaning the K+N to make sure I'm not starved for air. Had the local shop pull the codes from the computer, and he said he was getting an ICP code and a bunch of scanner gibberish that made him think there was an aftermarket chip or tuner in the truck (I bought it used but it has Banks diesel stickers all over the truck). His thought was that the Banks chips are junk and I probably just needed to yank the chip.

So today I pulled the PCM out and opened it up...and there's nothing un-stock or aftermarket inside. Nothing that says Banks, and from images I've seen on the net it appears my PCM is bone stock.

:censord:

Is it possible the PCM was reflashed or something else crazy that damaged it?

[najaf4life]

hey sorry I have no clue what is going on but hopefully someone or one of the techs will be able to help you out

[Jeff_Northon]

How many miles on the truck?

[Raul@Stealth Automotive]

have you made sure you dont have any leaks on your tubes? black smoke is unburnt fuel so your air to fuel ratio is off... spray some soapy water around all your boots and make sure their isnt any air coming out of those.... as for your question on maybe an aftermarket program on your rig it could be possible and no real way to find out..... either way if it did your boost numbers should be a lot higher than that.....

-Raul

[ProGunProgressive]

Hey guys,
About 123K on the truck.

I'll check for a vacuum leak on the intake, intercooler, etc. I can see that causing the sputtering.

That was my thought as well, a truck that makes 17lbs of boost can't have that much of an aftermarket tune anyway...pretty sure my truck just has the intake/exhaust and that's it.

[vitalidle]

Also check to see your exhaust back pressure valve is opening.

[ProGunProgressive]

Gotcha...how do I check that? What would cause it to stick?

Is the ICP code the scanner picked up a good indication that the problem is on the intake side?

[vitalidle]

I don't think your ebpv is the total fix sounds like you might have some injector problems as well, but thought it might be part of the reason your getting high egt's. It can get sooted up and stick shut. Its a butterfly valve on the back side of the turbo that shuts to aid it engine warmup and opens after the engine comes up to temp. If you look on your turbo pedistal there is a shaft coming out of the side that will actuate the valve. You should be able to slide the clip and move the valve with your hand. I will see if I have any pics on this puter to give you an idea.

[mschn99]

First thing i would look for.....look over the trans bellhousing from below and see if your Y pipes are leaking at the donuts by the turbo...

second thing i would do is take the EBP sensor tube off and clean it...see if its all plugged up with carbon...

[vitalidle]

This is the turbo pedistal. That is what your turbo sits on. The shaft Im talking about is right on the left back side. That is what actuates your valve. If you find that its shut if you can get it open and while the truck is shut down unplug the two wire plug that is plugged into the front of the pedistal. That is the soloinoid you can see in the front. That will disconnect electrically the valve and it will not be in use anymore. It might not have anything to do with your issues but its worth a shot.