Elitedownunder Posted November 30, 2016 Share Posted November 30, 2016 Guys, Just had a rebuild on my 94 CLR E7 454 VMAC1 runs sweet until you put your boot into it and the black smoke is awful. How do I stop this from occurring? The pump to engine timing was set up at 10 BTDC and with the use of the A/B black box. This motor spun a bearing but I did notice a day prior it started blowing the black smoke. I have checked all restrictions and even bypassed the spark arrestor (so a straight out pipe), still the same. I think my pump is a P7100 series Bosch but I am not sure and have added a pic of the plate. Any thoughts on how to solve this? Quote Link to comment Share on other sites More sharing options...
fjh Posted November 30, 2016 Share Posted November 30, 2016 Check the turbo! 1 Quote Link to comment Share on other sites More sharing options...
gearhead204 Posted November 30, 2016 Share Posted November 30, 2016 also check all the charge air couplers and after cooler, how's is your manifold pressure ? Quote Link to comment Share on other sites More sharing options...
Mackpro Posted November 30, 2016 Share Posted November 30, 2016 I vote low boost pressure as well. On those older engines, does the air compressor get its fresh air from the intake manifold like most of the ETECH's ? If so , the line coming off the intake manifold to the air compressor could have been left off. 2 Quote Link to comment Share on other sites More sharing options...
Elitedownunder Posted November 30, 2016 Author Share Posted November 30, 2016 What do I check on the turbo....there is a weep of oil going into the intercooler, and should the manifold gauge move when revved or only when under load? I have checked the line from the manifold and when I blow into it the gauge reacts. The line to the compressor is clear and its sucking or blowing from the manifold. I have attached pics of the turbos OEM plate and also another pic of the motor. Quote Link to comment Share on other sites More sharing options...
Mackpro Posted December 1, 2016 Share Posted December 1, 2016 I see the problem! Your steering gear box is on the wrong side of the frame! LOL. Just kidding! We always set up the pump timing 1 to 1.5 degrees above what ever it say on the valve cover using the A/B light that plug into the side of the injection pump. Any higher that 1.5 degrees we found that the engine will over heat in the summer months. Quote Link to comment Share on other sites More sharing options...
Elitedownunder Posted December 2, 2016 Author Share Posted December 2, 2016 I notice that the inter cooler hoses on the turbo side (or as the U.S call it hot side) both hoses tend to collapse as if being suck in when over 1200 revs is this normal or does it sound like a restriction is caught up? Quote Link to comment Share on other sites More sharing options...
hatcity Posted December 2, 2016 Share Posted December 2, 2016 Replace the hoses you mentioned. THAT may be the restriction. 1 Quote Success is only a stones throw away.................................................................for a Palestinian Link to comment Share on other sites More sharing options...
carlotpilot Posted December 2, 2016 Share Posted December 2, 2016 if i read right you say the hoses going to the aft.cooler side collapse then that would mean no air flow thru the turbo . with motor off check to see if turbo is free` if free check further toward breather for restriction Quote Link to comment Share on other sites More sharing options...
gearhead204 Posted December 3, 2016 Share Posted December 3, 2016 did some one put the air cleaners in upside down? the intercooler hoses should swell with load/rpm not deflate or collapse you most certainly have a problem on the intake side of the engine, also check to see if a shop rag has the turbo stuck! Quote Link to comment Share on other sites More sharing options...
Elitedownunder Posted December 3, 2016 Author Share Posted December 3, 2016 I have also damaged the fins and rails on the intercooler when I removed it with the fork. Quote Link to comment Share on other sites More sharing options...
carlotpilot Posted December 3, 2016 Share Posted December 3, 2016 time for a pro mechanic Quote Link to comment Share on other sites More sharing options...
Elitedownunder Posted December 3, 2016 Author Share Posted December 3, 2016 Yes, could be, Gearhead is right as I was saying the same if air is being forced into the intercooler it should expand the hoses not collapse...though I may have found the problem with this intercooler, will have to have it pressure tested but I want to stick a borescope down into it to see if a rag did not get sucked down. Quote Link to comment Share on other sites More sharing options...
fjh Posted December 3, 2016 Share Posted December 3, 2016 (edited) That collapses is common ! caused by turbo lag however they should suck in a bit then inflate , you should be sure the filters are clean and installed correctly and yup that coolers a good suspect! Edited December 3, 2016 by fjh Quote Link to comment Share on other sites More sharing options...
felicello122 Posted December 3, 2016 Share Posted December 3, 2016 Your cooler is bad I bet, the forks may have cracked the tubes, put a new air filter in while your at it Quote Link to comment Share on other sites More sharing options...
Elitedownunder Posted December 3, 2016 Author Share Posted December 3, 2016 Even taking the filter out as there is only one main filter, so there is no restriction it still sucks in the hose. Anyway I am out of money now to continue.... but I should be able to pressure test this intercooler myself with some couplings. Quote Link to comment Share on other sites More sharing options...
Dirtymilkman Posted December 6, 2016 Share Posted December 6, 2016 On 12/3/2016 at 5:15 PM, Elitedownunder said: Even taking the filter out as there is only one main filter, so there is no restriction it still sucks in the hose. Anyway I am out of money now to continue.... but I should be able to pressure test this intercooler myself with some couplings. I honestly don't think you'll be able to pressure test it yourself if that's how you removed it........... Quote Link to comment Share on other sites More sharing options...
dickbuick Posted December 6, 2016 Share Posted December 6, 2016 By the photo the charge air looks pretty bad But dose this truck have an exhaust brake as well as an engine brake (unit in the exhaust pipe by the bell housing) I had one the linkage fell off flap closed drove me nuts had all the same symtoms Quote Link to comment Share on other sites More sharing options...
Elitedownunder Posted December 6, 2016 Author Share Posted December 6, 2016 Hey guys, Yes still no joy and don't think it is the inter cooler, no exhaust brake dickbuick...though it has a spark arrestor on it but I removed the exhaust so it was a straight though pipe and made no difference. I am looking at pump and injectors I think. Quote Link to comment Share on other sites More sharing options...
gearhead204 Posted December 7, 2016 Share Posted December 7, 2016 ok, did you have the cam out? or the fuel pump off? have any of the front cover gears out ? I'm thinking possibly you are off by one tooth on the cam timing or fuel pump timing. Quote Link to comment Share on other sites More sharing options...
Elitedownunder Posted December 7, 2016 Author Share Posted December 7, 2016 Full rebuild so all of the above, but I set up the pump with the ab kent Moore black box.......can I still be wrong? Quote Link to comment Share on other sites More sharing options...
mrsmackpaul Posted December 7, 2016 Share Posted December 7, 2016 Ok I only have started reading this has any thought that perhaps some bits of the main bearing in the days leading up to it chucking the bearing ended up going thru the turbo Because if your making black smoke fuel isnt getting burnt so your not getting enough air to burn the fuel properly Paul Quote Link to comment Share on other sites More sharing options...
mrsmackpaul Posted December 7, 2016 Share Posted December 7, 2016 5 minutes ago, Elitedownunder said: Full rebuild so all of the above, but I set up the pump with the ab kent Moore black box.......can I still be wrong? It wont be this keep it simple you have un burnt fuel so you have a lack of air flow and its either plugged air filter (just remove the hose off the turbo and take it for a run if its better you know where to look Or maybe prove the inter cooler is fine just get some pipe the right size and replace it temporally with a pipe so you no the restriction isnt in the inter cooler but I dont think its that either I reckon you have sucked some bearing into the turbo and stuffed the bearing Paul Quote Link to comment Share on other sites More sharing options...
Elitedownunder Posted December 7, 2016 Author Share Posted December 7, 2016 if it was the turbo surely there would be some damage or bearing noise, though you maybe right... I will try by-passing the intercooler and see how it goes...see if there is any pressure coming from the turbo. Quote Link to comment Share on other sites More sharing options...
Elitedownunder Posted December 7, 2016 Author Share Posted December 7, 2016 (edited) found rags in the intercooler blocking the flow, all good now with heaps of manifold pressure...thanks guys Edited December 8, 2016 by Elitedownunder Quote Link to comment Share on other sites More sharing options...
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