So I got tired of smelling diesel in the Cab of the EX.

I had the spring kit in the truck for a few months....ok it was 7 months.

I read all the stuff I could find on here and the manual I have. I studied the job every time I had the hood open. I figured I could pull the upper hose out of the way, use a 1/4" drive ratchet and torx socket. Well that theory seemed good in my head.

The disassemble went great until my torx socket took a dive and landed between the frame and steering box. No problem I have another in the box. Get it apart and start matching parts up in the kit. I had an o-ring instead of a square looking o-ring that went on the black insert. Nothing major. Go to install and slips and drops between the block and PS pump. Should have put rags down! After removing the air filter, which BTW is huge compared to anything else I have worked on, I was able to retrive the insert and socket. I should have just removed the air filter and CAC pipe, but was intimidated being this is my first diesel.

So after getting it back together after an hour or so, I cycle the key a few times and start it up. No leaks or drips ! I am pumped. I let it warm up a few minutes and jump in it to run to get dinner for me and the boys. As I stepped into the pedal like I normally do I was getting a POP, POP. I let off and slowly back into it and POP,POP,POP! . After that I limped it to the store and let it idle while I got the food.

I got back in it and set my SG2 to VFD, MFD, ICP and boost. The VFD was 1.5-3.3 higher then the MFD. It stayed constant through out my test drive after getting dinner. The ICP was the same as always, 645 @ idle and 1000 @ 70 MPH on cruise. The boost is normally at .6-.8 at idle, now it is showing 1.1 at idle and the values are the same at normal driving before the blue spring mod. On the 10 mile run down the highway there was no popping what so ever. There is however a whine/whistle that was not there before. The only other thing is noticeably more black smoke on acceleration. As far as I know I do not have a bad injector. I have done a contribution test on it a few times since owning it.

I pulled the truck back into the garage and there are zero drips, the CAC boots look ok.

So can anyone point me in a direction to check?

Also the idle seems smoother and the injectors sound quieter after doing this.

 

Make sure you got all your wire connections hooked backup correctly, especially the MAF/IAT on the air intake hose.

 

everything is plugged in the way it should! No check engine light or codes.

 

Take a stick and put a string on the end and go fishing for a high
pressure air leak around the CAC tubes and boots.
You have the metal cold side CAC? If you have plastic you need
to check the bellows for cracks.

Sean

 

Have you cleaned your EGR valve yet? Unplug your EGR valve and see if the problem goes away.

 

Squirrel tail works better

 

Yep have the metal CAC pipe with the original boots. I checked the upper boot after driving it today.

 

For a minute I thought you were going to say you found tht in your CAC pipe!

 

Yes sir did that a few weeks ago. It was the first thing I did mechanically besides changing oil since I bought it.

 

Did you tighten the CAC tube clamps down with a torque wrench? What ft lbs did you use?

 

In the housing the fixed Oriface has a tube was all of that Intact and not cracked? Look in the tech folders Rusty has a write up on Blue spring Install, Just a few things to look back into

 

Did not remove it! didn't check it!

 

It takes a lot to get a CEL on an 03 and the SGII most likely won't read codes on your truck so you could have codes despite not having a CEL. You probably should take it to a parts store to get the codes read or find someone with a more powerful code reader.

 

I have a scanner besides the SG2 and it is not showing anything at all.

Truck started up fine this morning and afternoon. Drive like it should.