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Old 09-26-2018, 10:36 AM   #1 (permalink)
Tahoe2DRDC
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Black Smoke - Bad Wastegate?

HI,
I have a 1999 6.5L with about 300K miles that puts out a lot of black smoke when I accelerate. I think it's something with the wastegate or EGR but looking for help to diagnose.

I got code P0236 (Turbocharger Boost Sensor A Circuit Range/Performance.) I replaced the Wastegate solenoid and cleaned the inside of EGR valve as best I could and the codes went away, but not the black smoke. I get the correct vacuum from the pump (the needle is steady at 25 in-Hg) and about 14/15 in the wastegate line, the needle fluctuates. Should it fluctuate? With the solenoid removed, should I be able to blow through it?

The wastegate actuator arm moves when the engine is off and is pulled up when the engine is idling. Is there more I can check? Is it possible to take the wastegate apart?

Previous Issues/History:
-When I bought the truck, it showed code P1653, would idle fine but rev up to redline if I tapped the gas pedal. I replaced the PMD and the run-away RPMs went away after 10 or 20 restarts.
-The injector pump was replaced by a previous owner. (I have the old pump if anyone wants it) Could the issue be injector timing?
-Could black smoke be leaking injectors?

Thanks for reading.

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Old 09-26-2018, 10:41 AM   #2 (permalink)
OkDually
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1996 K3500 6.5L,( "F" Eng #141 cast block) 5 speed manual, crewcab, dually longbed: 208,000mi.
Diamond Eye 4" Turbo Back Exhaust w/2.5" Flo-Pro Crossover
AirDog II DF165 w/ tank sock delete - XDP
TD-Max boost controller - Kennedy Diesel
OPS extension hose - Leroy Diesel
Glow Plug Harness- PT Wiring Solutions
Glowshift Maxtow EGT,Boost, Fuel gauges
Boost & Fuel Pressure Bolts - Leroy Diesel
2/0 Battery Cable Upgrade - PT Wiring Solutions
PMD w/#9 resistor and Re-Location Kit, mounted to bumper - Leroy Diesel
GM-5 Turbocharger
4.10 gear ratio
OptiLube summer + Formula


Proud member #1039 of The 3500 Dually Club

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Old 09-26-2018, 02:33 PM   #3 (permalink)
OkDually
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If you installed an aftermarket wastegate solenoid, that may be an issue.
Aftermarket electrical parts bring gremlins in a 6.5L


The solenoids are also known to stick out of the box.
You can try spraying a little WD 40 into the vacuum end of the solenoid and then giving it a few light taps to see if the internals will loosen up.

Also, verify that you have 12v. at the solenoid connector
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1996 K3500 6.5L,( "F" Eng #141 cast block) 5 speed manual, crewcab, dually longbed: 208,000mi.
Diamond Eye 4" Turbo Back Exhaust w/2.5" Flo-Pro Crossover
AirDog II DF165 w/ tank sock delete - XDP
TD-Max boost controller - Kennedy Diesel
OPS extension hose - Leroy Diesel
Glow Plug Harness- PT Wiring Solutions
Glowshift Maxtow EGT,Boost, Fuel gauges
Boost & Fuel Pressure Bolts - Leroy Diesel
2/0 Battery Cable Upgrade - PT Wiring Solutions
PMD w/#9 resistor and Re-Location Kit, mounted to bumper - Leroy Diesel
GM-5 Turbocharger
4.10 gear ratio
OptiLube summer + Formula


Proud member #1039 of The 3500 Dually Club

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Old 10-02-2018, 05:39 PM   #4 (permalink)
Tahoe2DRDC
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I checked the current at each of the solenoid connectors:
Wastegate was 13.6V
EGR was 13.8V
EGR Vent was 13.8V

Next I checked the vacuum levels at points before and after each solenoid:
25 inHg from the vacuum pump
16 inHg at the wastegate (went up to 20 when I revved the engine)
18-22 inHg in the line going into the middle/EGR solenoid, but the vacuum gauge needle bounced around a lot
16 inHg in the line going to the MAP sensor front the rear solenoid
4 inHg in the line going to the EGR valve
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Old 10-02-2018, 06:23 PM   #5 (permalink)
OkDually
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Install fresh air and fuel filters if you have not already done so and then check your exhaust ( pre turbo) for any leaks..
Double check all grounds
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1996 K3500 6.5L,( "F" Eng #141 cast block) 5 speed manual, crewcab, dually longbed: 208,000mi.
Diamond Eye 4" Turbo Back Exhaust w/2.5" Flo-Pro Crossover
AirDog II DF165 w/ tank sock delete - XDP
TD-Max boost controller - Kennedy Diesel
OPS extension hose - Leroy Diesel
Glow Plug Harness- PT Wiring Solutions
Glowshift Maxtow EGT,Boost, Fuel gauges
Boost & Fuel Pressure Bolts - Leroy Diesel
2/0 Battery Cable Upgrade - PT Wiring Solutions
PMD w/#9 resistor and Re-Location Kit, mounted to bumper - Leroy Diesel
GM-5 Turbocharger
4.10 gear ratio
OptiLube summer + Formula


Proud member #1039 of The 3500 Dually Club


Last edited by OkDually; 10-02-2018 at 06:24 PM.
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Old 10-31-2018, 02:28 PM   #6 (permalink)
Tahoe2DRDC
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I replaced the air and fuel filters. I'm not sure how or where to check grounds.

I used this diagram to check vacuum levels at points along the system. Most seems OK; 25 in-Hg from the pump, 15 in-Hg to the wastegate, 20 in-Hg from the PWM solenoid to Vent Solenoid, 15 in-Hg to map sensor. However, only about 4-5 in-Hg in the line to the EGR valve.

As an experiment, I disconnected and plugged that line. the truck runs better with less black smoke. No engine light codes yet but I haven't had a chance to drive around very much.
Attached Images
File Type: jpg Vacuum Solenoid Diagram.jpg (14.5 KB, 21 views)
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Old 10-31-2018, 02:36 PM   #7 (permalink)
OkDually
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Here is a link with pics on grounds:
https://www.dieselplace.com/forum/sh...d.php?t=163087

Remove each ground, clean the contact points and reconnect.
Replace any that are in bad shape..
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1996 K3500 6.5L,( "F" Eng #141 cast block) 5 speed manual, crewcab, dually longbed: 208,000mi.
Diamond Eye 4" Turbo Back Exhaust w/2.5" Flo-Pro Crossover
AirDog II DF165 w/ tank sock delete - XDP
TD-Max boost controller - Kennedy Diesel
OPS extension hose - Leroy Diesel
Glow Plug Harness- PT Wiring Solutions
Glowshift Maxtow EGT,Boost, Fuel gauges
Boost & Fuel Pressure Bolts - Leroy Diesel
2/0 Battery Cable Upgrade - PT Wiring Solutions
PMD w/#9 resistor and Re-Location Kit, mounted to bumper - Leroy Diesel
GM-5 Turbocharger
4.10 gear ratio
OptiLube summer + Formula


Proud member #1039 of The 3500 Dually Club

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Old 11-01-2018, 12:34 PM   #8 (permalink)
ak diesel drive
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should have full vacuum to wastegate at idle I'd suspect the lines are leaking
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Old 11-01-2018, 01:17 PM   #9 (permalink)
Sirleitet
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Pull the wastegate line at the egr thing at the intake while running on idle. The truck should surge slightly once, if not, something is wrong.
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Mods: Racor 690r fuel filter/w heater, new front face, new radiator and support bushings. Repaired both cab corners & frame. (Rust.)
Relocated PMD, DIY extended wiring harness. # of PMD replaced since owned truck in 2013: 5.
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