Hello all,

04.5 LLY having issues with runnability. The truck started running really rough after filling up with diesel about 25 miles previous. I was able to limp it home but it was running extremely rough and blowing bluish smoke at an idle. I did an injector balance test and found injectors 1,2 and 3 not to be working. I pulled injector 3 since it was the easiest to get to and I have posted some pictures of what it looked like. When removing the intake manifold I also found a large buildup of oily/carbon buildup...wondering what could be causing this? The truck has 105,000 miles on it. Should I drain all the fuel, replace fuel filter and replace all the injectors? Do I have another issue going on with the build up in the manifold? Any help is appreciated...thanks!

http://img.photobucket.com/albums/v480/Braz475/DSC09855.jpg?t=1252707225
http://img.photobucket.com/albums/v480/Braz475/DSC09856.jpg?t=1252707260
http://img.photobucket.com/albums/v480/Braz475/DSC09857.jpg?t=1252707292
http://img.photobucket.com/albums/v480/Braz475/DSC09861.jpg?t=1252707313
http://img.photobucket.com/albums/v480/Braz475/DSC09863.jpg?t=1252707338
http://img.photobucket.com/albums/v480/Braz475/DSC09864.jpg?t=1252707354

Hello all,

04.5 LLY having issues with runnability. The truck started running really rough after filling up with diesel about 25 miles previous. I was able to limp it home but it was running extremely rough and blowing bluish smoke at an idle. I did an injector balance test and found injectors 1,2 and 3 not to be working. I pulled injector 3 since it was the easiest to get to and I have posted some pictures of what it looked like. When removing the intake manifold I also found a large buildup of oily/carbon buildup...wondering what could be causing this? The truck has 105,000 miles on it. Should I drain all the fuel, replace fuel filter and replace all the injectors? Do I have another issue going on with the build up in the manifold? Any help is appreciated...thanks!

http://img.photobucket.com/albums/v480/Braz475/DSC09855.jpg?t=1252707225
http://img.photobucket.com/albums/v480/Braz475/DSC09856.jpg?t=1252707260
http://img.photobucket.com/albums/v480/Braz475/DSC09857.jpg?t=1252707292
http://img.photobucket.com/albums/v480/Braz475/DSC09861.jpg?t=1252707313
http://img.photobucket.com/albums/v480/Braz475/DSC09863.jpg?t=1252707338
http://img.photobucket.com/albums/v480/Braz475/DSC09864.jpg?t=1252707354

Wow, I really need to block my EGR.
Please fill out your signature so we know what you're working with.

Hey!

I have the EGR blocking plate in the garage and was wondering if I should put it in. But if this is why you block it I am doing this asap. I wish someone else would chime in so we could figure out that the EGR is the problem.

all i gotta say is...wow...yes u deff. need to block that EGR and do a PCV reroute asap...you may wanna pull all injectors to check them out bc if 3 injectors look like htat, then i would bet the rest are in bad shape to. that intake manifold is very bad, i would try to clean all of it out as best as u could, or u could buy a better one(which ever u prefer) but i would deff do a egr block and a PCV reroute.

So you guys think doing an EGR block off and PCV reroute will prevent this build up from reoccurring? As far as the injectors go...will they need to be replaced or can you clean them/rebuild them? Is this common for a truck with only 100,000 miles???

yes doin the block off and PCV reroute with deff prevent this in the future. the egr is the biggest bc it is allowing ur exhaust to enter back into the intake. if it was me, i would just go on and replace them but u may want to ask around about cleaning, like search this site or call a diesel performance shop and ask them or just wait and im sure someone on this site will give insight on if the injectors can be cleaned. as for it being common for a truck with ur milage...its just one of those things that happens

ordered EGR blocker and PCV reroute kit today....obviously it's gonna be worth it's weight in gold and worht every bit of time and hassle to install if it's gonna save me from this!

ordered EGR blocker and PCV reroute kit today....obviously it's gonna be worth it's weight in gold and worht every bit of time and hassle to install if it's gonna save me from this!



Where did you order these from, if I can ask?

i was wondering if the manifold will clean itself when the blocker plate is installed? or if you would have to yourself?

i was wondering if the manifold will clean itself when the blocker plate is installed? or if you would have to yourself?

no no no no no lol you will have to clean it urself. even if u install that blocker plate, all that gunk will go straight into the engine.

It is believed that over time the intake will clean itself... but I don't believe I've ever seen any pics that clearly demonstrate this. Now... if you had a water/meth injection setup, then maybe...

I don't think you will see much if any self cleaning. The only thing flowing thru the intake should be fresh air and that does not do much for cleaning. THe fuel is injected so any additive is only going to clean fuel lines and possibly some of the combustion chamber. I have my egr blocked but have not messed with the pcv yet. I have not thought the pcv to be as big a deal. True it can leave an oily residue on the inside of the intake but it should not make a build up like you are seeing. That comes from the egr and it's dirty air that is let back into the motor. If you are letting an oil mist mix with clean filtered air you should not see a build up of gunk like that. PCV lines have been plumbed into the air intakes for years, my old carbureted 1970 has a pcv and was connected from the valve cover to the filter housing on top of the carb.

I don't think you will see much if any self cleaning. The only thing flowing thru the intake should be fresh air and that does not do much for cleaning. THe fuel is injected so any additive is only going to clean fuel lines and possibly some of the combustion chamber. I have my egr blocked but have not messed with the pcv yet. I have not thought the pcv to be as big a deal. True it can leave an oily residue on the inside of the intake but it should not make a build up like you are seeing. That comes from the egr and it's dirty air that is let back into the motor. If you are letting an oil mist mix with clean filtered air you should not see a build up of gunk like that. PCV lines have been plumbed into the air intakes for years, my old carbureted 1970 has a pcv and was connected from the valve cover to the filter housing on top of the carb.

The oily mist from the PCV will accumulate in the boost tubes and intercooler, ultimately making it easy for the boots to blow off under power... which will result in you having no power. There are legitimate reasons for rerouting the PCV... regardless of your circa 1970's car (I doubt it was turbocharged).

I don't argue that there are reasons for rerouting, I just don't think it's as big an issue as pumping dirty air back into the engine.
You are correct, the old truck was not turbo charged, I just never noticed a lot of oil in the air cleaner compartment either. If I were to relocate it, I would think about connecting it to the air box some way. If you just disconnect the hose and reroute it to open air it's not really pcv any more, more like just cv.

If you connect it to the air box, it will mess up the MAF sensor and the oil fumes will still run through the entire system just as a stock one does.-- No advantage or improvement!

Once the air system get coated on the inside, it will not clean itself-- the only way to clear them out, is to remove the parts and physically clean them with solvent or other!

UPDATE:

Replaced all 8 injectors and now #2 is firing but #1 & #3 are not. Any ideas? Can a blown headgasket cause something like this or should I be looking at electrical? Thanks

first i would check all electrical wiring to these injectors. did you replace all the injector electrical connectors?

any news?

Ended up being a broken rocker arm

oh dang that sucks man. you doin the repair work urself?

Ended up being a broken rocker arm
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