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Smoking, Knocking, PMDing...

A

abumariah

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Hey guys, i got brought over from Dieselplace today...here is my post from over there...seems the talent is hyar now.

0. Describe in detail the problem you are having. Please be as descriptive as possible. BLACK SMOKE AND KNOCKING UPON ACCELERATION, ERRATIC ACCELERATION
1. Does the engine crank, or 'turn over'? YES
1a. Does the engine start and run? YES
1a1. If the engine does not start - Crack injector line: do you have fuel? Yes/No
1b. Do you have a Wait To Start Light & the amount of time (seconds) lit. YES...5 SEC.
1c. Ambient Condition (temperature outside indicate F or C) _____ ° 80 F
1d. Engine Cranking speed (if you have an accurate tachometer). NORMAL
1e. Are you experiencing stalling? NOT ANYMORE...YET
1f. If Stalling, describe (upon startup only, down the road, hit a bump etc) DOWN THE ROAD
1g. If Stalling, do you notice loss of dash or instruments? NO...WAS PMD HARNESS...SEE BELOW
-note if experiencing stalling,you must indicate PMD location in #24.

1h. Check turbo inlet and air filter for obstructions. Cone filters have lost disk and stopped air to turbo. ORIGINAL AIR FILTER
1i. In a no-hot start, pour a bottle of room-temp water on the injection pump. Does it start now? yes/no
1.1 Lift pump test - describe results LIFT PUMP WORKING PROPERLY
2. Service Engine Light while running?- on/off/intermittent NO
2a. Service Engine light does glow during start/cranking/bulb check: Yes/No DNK...WILL CHECK
3. Model year 1995
3a. Odometer reading (indicate if in miles or km) 195K...(WILL UPDATE PROFILE TONIGHT)
3b. Miles on major engine components if been replaced (example Injection pump) DON'T KNOW
3c. Indicate the model number on the Injection pump (starts DS4 or DB2......) WILL CHECK
4. Have you scanned for engine codes? (varies by pre/post 96) yes/no NO
5. List exact results on engine codes:
6. Air Filter condition (visual check) DIRTY
7. Fuel filter condition (freshly changed/condition unknown/mileage since changed) FRESHLY CHANGED
8. Condition of Battery terminal connections (removed, cleaned and tightened) CLEAN AND TIGHT
8a. Known condition and age of the batteries. 1 YR
8b. Are batteries of differing age or are they a matched set? MATCHED
8c. Condition of Major Grounds. (same drill as batt - removed, cleaned, retightened) SEEM TO BE CLEAN
9. Upon cold start, does the radiator hose get hard quickly? Yes/no WILL CHECK
10. Upon cold start, do you have excessive white smoke? Yes/no NO
11. Do you have excessive cranking time before the engine starts? NO
12. Have you used the block heater, and does this effect engine starting?(only try for starting problems) N/A
13. During hard acceleration, do you have excessive black smoke? Yes/no YES
14. Do you have any unusual exhaust smoke issues? SMOKES LIKE A TUGBOAT
15. Turbo check out - pass/fail PASS
16. Do you have an EGR on the engine? (An F or an S engine code 8th VIN digit) S CODE
17. Indicate if you know if it’s a 1500, 2500, 2500HD, 3500, 3500HD. 2500
18. Indicate fuel that you are using: Bio-diesel, #2 Diesel, #1Diesel, SVO/WVO, other #1 DIESEL
18a. If running a VO (Veggie Oil fuel) setup, indicate details of your conversion (homemade, or packaged system)
19. Are you using any fuel additives? If so, please list. NO
20. Please indicate geographic region you are in: (example: Texas or Canada) KENTUCKY
21. Do you have any service history available that might pertain to the problem you are having? NO
22. Please indicate any modifications to the vehicle that might help us diagnose better. ALL ORIGINAL
23. Upon unscrewing the fuel cap, do you have a large vacuum formed in the tank? yes/no NO
24. Location of PMD/FSD? On the pump/remoted over intake/remoted out of engine bay (please specify placement specifically) REMOTE...SEE BELOW
24a. If remote mounted, describe wiring harness (homemade or purchased from a vendor?) WAS PURCHASED, NOW JURY RIGGED
24b. Indicate the location and condition of the FSD/IP grounding wire. INTAKE MANIFOLD AREA
25. Are ALL glow plugs in proper working order as per this thread? YES

Per notes above, the PMD is a DTech with a Pensacola Diesel relocation kit in the front bumper.


Alright, so I had a diesel fuel leak for a couple of months (I know, but life's been hard since that ice storm down here this winter) and the truck started to smoke before I fixed it. It was leaking at the t-valve drain up by the front of the intake manifold.

Fixed the leak two weeks ago and replaced all flexible fuel hoses.

anywhoo...it was starting to give off some black smoke which got worse over time. After i replaced the fuel hoses I had it stall on me. Wiggling the pmd harness fixed the problem. then it happened last friday on the interstate away from home. I plugged in my old PMD into the original harness and managed to get off the interstate into a Walmart parking lot.

long story short, i unplugged the Pensacola Diesel harness where it plugs into the original harness on top of the intake manifold and there was a pin burnt out on both harnesses. I don't know if it got diesel in there during the leak or what, but it was definitely malfunctioning at the harness connection. I cut the plugs off the harness and reconnected the proper wires together with wire nuts and tape and off we went with no problems. The black smoke even went away temporarily.

then the smoke started to come back same as before...it smokes black at idle, it smokes pretty good under high torque, low RPMs, and if you mash the gas pedal it will give you a getaway smokescreen that frightens the folks behind me. And it knocks pretty good at low RPM acceleration loads.

I took the harness apart where I "repaired" it and the wires seem to be fine, the harness plug is fine at the PMD in the bumper.

I plugged the old PMD in under the bumper and the issues stay the same.

Any help is much appreciated and I will be sure to finish the checklist tonight or in the morning if there's something I missed.

Thanks again!
__________________
1995 K2500 4x4 6lug 6.5TD "S" Engine Extended Cab Short Bed 197000 mi...
 
I think your problem is with something other than the PMD. You have lots of unburnt fuel going on there, could be waste gate malfunction, turbos not spooling up or something of that nature. I have never heard of a PMD causing black smoke, but that said, doesn't mean it never has.
 
thanks for the tips guys...i'll get on that tomorrow. I had searched all the black smoke threads i could find and no one mentioned any knocking that only occurred under acceleration and that really was my concern.

NVW...did your truck knock like that?

thanks again fellas.
 
The knocking could be the vacuum pump taking a dump. That would account for the lack of boost pressure due to wastegate failure (no Vacuum). Mine did this recently, and was a loud ticking/knocking sound.
 
Knocking under acceleration sure sounds like an injector stuck open to me. Usually results in white smoke, not black, but an injector that is stuck open will pre-detonate the chamber early and when it happened to me it sounded a whole lot like the cold advance knocks when starting the engine when its frigid outside.

Picture the piston coming up, and fuel is already there, then it ignites that fuel before its at its top of its stroke, knock, then the injection pump pumps in the remaining fuel, but that cylinder already fired, or is firing, throwing the timing of that cylinder early.
 
I have read that about injectors, although the white smoke thing caused me to disregard that as a potential problem. I don't really understand the stuck open thing either...do the individual injectors themselves have actuators?

I believe I understand the basics of the turbomaster idea. Say i could get one built tomorrow, could i just plug the vacuum lines up and run the truck that way? Will the EGR system cause serious damage to the fuel system if I don't bypass it immediately or should i be able to commute while i do this one step at a time? I understand that it would mean loss of fuel economy, but i'm only getting 16 as it is what with blowing all this diesel out the pipe.

thanks again fellas.

jc
 
Disconnect the vacume hose to the egr valve and plug it to see if the smoking goes away. I'd ditch the s intake and replace with a f intake. I recently saw what the erg was doing to my 95 2500 ld. The intake and ports in the head were more than half plugged with soot.
 
Check the codes, its free.
Should have a vac/fuel pressure gauge, like $20, and check vacuum at the wastegate and coming from the vac pump.
Do you have boost gauge?

I used to have the smokescreen affect, and after replacing injectors and IP it totally went away, completely. So that meant either the timing on my previous IP, which I didnt check was retarded a lot, or my injectors were dumping in too much fuel, like pop pressure was just too low, and not necessarily stuck open. And I think they would drip overnight because Id get a big puff on startup.

Other most likely cause, if there is no air restriction on intake, is an exhaust restriction. tear off the catalytic converter, gut the EGR in the intake and block it off. The ticking could be an exhaust leak caused by restirction.
 
abumariah said:
thanks for the tips guys...i'll get on that tomorrow. I had searched all the black smoke threads i could find and no one mentioned any knocking that only occurred under acceleration and that really was my concern.

NVW...did your truck knock like that?

thanks again fellas.
Click to expand...

I wouldn't call it a knock but it ran rough, almost like a miss. I really babied it until I got home to fix it.

Leo
 
i plugged the egr vac hose and valve, still black smoke...the wastegate lever has quite a bit of pressure when running, i can move it but it takes quite a bit of effort...does that mean the problem is NOT with the wastegate solenoid or vacuum pump?
 
Glad you make it here.

My suggestion is to check all the vacuum parts like hoses, etc. I am not familiar with EGR but I suspect there is an EGR solenoid also. May want to check that.

If you want to plug it properly, I am sure somebody here has done it before that can give you the how to.
 
well, i jumped the gun and you were right BK...i plugged the egr and hose and when i first started this am it was dumping smoke still, but it cleared up after about five minutes and the knocking went away.

hallelujah. now i just have to deal with the smokescreen i get when i punch it on the interstate. i'll start going through the components beginning with the cat (i'm sure all that diesel dumped through it this past month has it pretty full of soot) and see what i can do to increase performance.

thanks again for getting me over here JMJ. you guys rock!!
 
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