This truck is starting to get me upset. I have posted a couple threads on '94-1/2-'97 and not much help. These truck are similar so hoping someone reads with ideas. I have performed some tests and done some research and started dismantling the truck. Valve covers and turbo off.
I believe I have some mechanical and unrelated electrical issues at same time.


'95 PSD 5 speed. 174,XXX with the turbo, UVCH and outside wiring, 2 inj. changed in 2 years/15,000 miles. No chip or tuner EBPV brake used, 120 volt, 3 year old IDM.

Truck was used plowing snow 2 weeks ago, another guy driving but I never noticed problems while next to it running. Next morning started truck, lots of smoke, missing and definite injector knock sound, no whoosh sound at that time. Removed valve covers looking for whatever, this was AFTER A/E said passed buzz test and when warm at operating temp the smoke disappeared and it passed contribution test. Unplugging inj. found no change with #3 inj. all other inj. the engine noticeably missed worse with disconnecting each. Rigged up 120 volt pilot light as noid light and it flashed on all cyl.s the same. Unplugged/plugged up #3 and it started firing??? Did buzz test again and #3 and #8 High to low side out.

During all this truck starting making whoosh sound never stopped smoking just for grins I performed compression test cold ( removed all glow plugs first) and thought I would retest when warm. During all this I found that 4 out of 8 glow plugs bad, replaced and started and the whoosh sound is REAL loud now and unplugging the EBPV does nothing to affect it. Having someone else start it and activate EBPV/Brake and rod does not move either.

Compression cold was between 290-340 all 8. Truck is really not bad shape and I feel the comp. isn't bad for cold, but I'm seriously thinking C4.

I could really use suggestions and would really appreciate all comments.
__________________

 

When I removed my turbo for replacement, I exercised the EBPV because it got stuck a couple of times while driving in decel tune. I discovered that it was easy for my EBPV valve to get stuck closed, so I did a little burnishing on the part that would bind. The problem never returned after that.

As for your injectors, that sure sounds like a bad UVCH, bad VC gasket, or something going on with the connector to the engine. We have a 42-pin connector to the engine and this is where I suggest to do a real continuity test for the injector solenoids and wiring.

 

Thanks Tugly! I will look at this in a little while. And try continuity tests. I spoke to someone yesterday eve about the turbo issue and he said it sounded like the bearing/seal inside was gone to allow the oil/smoke problem and perhaps the solenoid was bad on EBPV.

I have a turbo and pedestal off the '00 engine I have and that engine was pulled because of a stuck valve and loss of comp. I'm replacing the valve guides for a spare set but wondering about the turbo for a swap?