1.Describe the problem you are having in detail:
Truck starts fine, but doesn’t rev up at all. Even if I wait until the engine is completely warmed up, it still only revs to about ¼ throttle, then holds. This happens in park, neutral, and drive. Top speed is around 25 mph. Engine is throwing no codes at all. Cross over pipe, fuel filter, trans input speed sensor, and vehicle speed sensor (on xfer case) have all been replaced. There does seem to be a fair amount of pressure being sent out the hole from the CDR valve. It is strong enough that with the valve removed, it isn’t possible to stick a rag in the hole because it blows it back out. I don’t know if this is related or not.
2. Year of truck/engine.
1994 K2500, 6.5TD, 4L80E
3. Odometer reading (indicate miles or kilometers).
302k miles
4. Indicate the model number on the Injection pump (starts DS4 or DB2......).
5. Indicate if you know if it’s a 1500, 2500, 2500HD, 3500, 3500HD.
2500
6. Do you have an EGR on the engine? (An F or an S engine code 8th VIN digit)
Yes, F in 8th VIN digit
7. Air Filter condition (visual check).
Brand new
8. Fuel filter condition (freshly changed, mileage since changed).
Brand new
9. Location of PMD/FSD (http://www.dieselplace.com/forum/showthread.php?t=39436)? (ex. on pump/remote over intake, behind bumper).
FSD Cooler, remote over intake
9a. If remote mounted, describe wiring harness (homemade or purchased from which vendor).
FSD Cooler
9b. Indicate the location and condition of the FSD/IP grounding wire.
No idea
10. Outside Temperature (C or F). _____ °
55 deg F
11. Service Engine Light while running?- on/off/intermittent
None
11a. Service Engine light does glow during start/cranking/bulb check: Yes/No
Yes
12.Have you scanned for engine codes? Yes/No
Yes, no codes
12a. List exact results on engine codes (http://www.dieselplace.com/forum/dtc.php).
No codes
13. Condition of Battery terminals (removed, cleaned and tightened).
Removed, cleaned, and tightened
14. Known condition and age of Batteries.
2 years old
14a. Are batteries a matched set of same age?
Yes
15. Condition of Major Grounds (http://www.dieselplace.com/forum/showthread.php?t=157085) (removed, cleaned and tightened)
Clean and tight
16. Does engine crank, or "turn over"?
Yes
16a. Does engine start and run?
Yes
17. If engine does not start- Crack injector line (http://www.dieselplace.com/forum/showthread.php?p=2188140#post2188140): do you have fuel? Yes/No
N/A, engine starts every time, warm or cold.
18. Does your Wait To Start light come on?
I assume this is the glow plug light. It comes on
18a.Number of seconds WTS light is lit.
5-10 seconds
19. Engine Cranking speed (if you have an accurate tachometer).
No accurate tach (factory is dead)
20. Are you experiencing Stalling?
No
20a. Describe the event (upon startup only, down the road, hit a bump, etc...)
Engine cold or warm
20b. Do you notice loss of dash or instruments?
No
21. Check turbo inlet and air filter for obstructions.
None, turbo spins
22. In a no-hot start, pour a bottle of room-temp water on the injection pump. Does it start now?
23. Lift pump test (http://dieselplace.com/forum/showthread.php?t=39350) - Describe results.
Lift pump is working correctly after test
24. Upon cold start, does the radiator hose get hard quickly? Yes/No
Haven’t tested
25. Upon cold start, do you have excessive white smoke? Yes/No
I don’t notice anything.
26. Do you have excessive cranking time before the engine starts? Yes/No
No
27. Have you used the block heater? Does it affect engine starting? (only try for starting problems).
28. Are all glow plugs in proper working order (http://www.dieselplace.com/forum/showthread.php?t=39182)?
Haven’t tested
29. During hard acceleration, do you have excessive black smoke? Yes/No
Truck won’t accelerate hard
30. Do you have any unusual exhaust smoke issues?
If anything, I think the smoke during idle would be considered white smoke.
31. Turbo check out (http://dieselplace.com/forum/showthread.php?t=39368) - Pass/Fail
Pass
32. Indicate fuel that you are using: Bio-Diesel, #2 Diesel, SVO/WVO, other
No idea
32a. If running Veggie Oil fuel setup, indicate details of your conversion (homemade or packaged system).
N/A
33. Are you using any fuel additives? If so, please list.
N/A
34. Upon unscrewing fuel cap, do you have a large vacuum formed in the tank? Yes/No
No
35. Do you have any service history available that might pertain to the problem you are having?
No. I was told injector pump was replaced in the last 2 years, but that’s about it.
36. Please indicate any modifications to the vehicle that might help us diagnose better.
None, stock except for FSD cooler.

Strange one...Excessive exhaust back pressure from a collapsed muffler???

No power and severe crankcase back pressure...

Did this happen suddenly or all at once?

X2 on exhaust issue, Soot trap full?

Holes in pistons, bad rings? Excessive blow by is from something.

Disconnect the turbo downpipe and see if the engine will rev up. Then do a compression test.

Possible timing is way advanced?

No power and severe crankcase back pressure...

Did this happen suddenly or all at once?

I bought the truck like this. It did have some sensors unplugged and more that needed to be replaced, so I managed to get 15 check engine lights to go away...

X2 on exhaust issue, Soot trap full?

Is there a way to check this?

Holes in pistons, bad rings? Excessive blow by is from something.

Disconnect the turbo downpipe and see if the engine will rev up. Then do a compression test.

Possible timing is way advanced?

I'll try disconnecting the downpipe later today, I hope I don't have holes in the pistons or bad rings... The truck sounds right when it is idling, it just doesn't go anywhere from there...

Is there a way to check this?




Yes, disconnecting the exhaust from the turbo will eliminate the soot trap aka catalytic converter and muffler from the ‘system’ for testing. Search soot trap for pics of how the cat plugs up, you can see it if you take the exhaust apart.

Engine running fine doesn’t mean you don’t have cracked pistons or shot rings. Something is causing a lot of blow by in the crankcase. A compression test will eliminate this. It may not be relayed to the no rev up/power issue. But it sounds bad enough that one would suspect worn out rings. No compression = no power.

Found online that it could be bad sensors in the accelerator pedal position sensor, so I replaced that and have no change... Haven't had time yet to take the exhaust apart so I haven't eliminated that side of it yet.

check for seized turbo as well.

check for seized turbo as well.

Turbo spins at idle, speeds up with the little bit the engine will rev, and slows down when the wastegate is opened.

Do compression test and cat test as suggested by wa rwagon

I love you guys.... lol. I was lucky and all 4 bolts from the downpipe to the rest of the exhaust came off. Started the truck up, and she runs great! I guess the soot trap must have been that clogged. I haven't checked the engine CDR valve yet to see if I still have excessive crankcase pressure, but after driving it around the neighborhood and hearing the sound of the exhaust, I'm in love... :)