So I have a cxracing IC - it's actually Fullforce diesel, but they look identical so I'm assuming they are - just rebranded. With stock injectors, a few mods, custom tunes - no issues with EGTs.

Now that I have added 200/30 injectors and kc300x 63/70 (stage 1) turbo - I'm having horrible issues with EGTs loaded/unloaded. I can keep them in check unloaded but I have to really really watch how much throttle I use because in 3rd gear (automatic 3.55 gearing, stock tires) if I go over 3/4 throttle I'm pegging EGT gauge (just an expression, it gets toasty, I've seen it go over 1500 - it does cool down almost instantly)

KC turbo swears I shouldn't have this issue with stage 1 turbo, tuners say I shouldn't have EGT issues - I've tried 3 different tuners, SDK, Jelibuilt, and Andrew with AA. So I'm left thinking I may have an inefficient IC - which could be totally in left field, I honestly have no idea without having another to try!
Before I spend the money to replace my intercooler with another, I wanted to see what others thought - and what I could do to alleviate the issue.

 

Money of mine still on the IC core itself, either big pressure drop across it or poor fin per inch count. There is a reason my air to water on my BMW has a Bell core.

Have you checked your exhaust manifolds for leaks at the head?

 

I've replaced a gasket on 1 of the manifolds as there was a snapped off bolt that caused a leak, no signs of leaks on the exhaust side that I'm aware of, the up pipes have been replaced with frickin dorman pipes (was not my choice on what was put in, I didn't know they changed them until I picked it up from having the transmission rebuilt)
I'm not really sure how to check them though, like I say there's no signs of leaks.

I have an appointment Monday with a shop to put it on the dyno and try to find EGT issue - but I'm not sure if it's the IC they'll be able to tell me anything or not? I have no idea - not sure if they can help or not.

 

Do you read boost off the MAP sensor or do you read it off a probe for the Edge? If the probe, maybe you can do it on the inlet side of the IC and check engine pressure on the outlet via the MAP to find pressure drop.

Dorman eh, but at least they do not leak.

 

I have dieselsite boost fooler, MAP hooks to 1 side, separate probe on the other to read from Edge.

I have been tempted to check pressure on the other side - not sure how I would add a nipple into the IC pipe, and tap it to put it in.... it's very thin pipe

 

Several years ago I bought the Diesel Innovation IC for $1300 hoping like hell I could control my EGT's. It didn't help much and its one of the best IC's out there. If you ever find out what the problem is be sure to let us know. I'm only running 160/0's and have a problem when towing heavy. I think its just the nature of the beast. Also let us know how the dyno went!

 

I'm having the issue empty and loaded. I'm glad you mentioned your IC, when I wrote this I was thinking of your truck actually - I went and found your signature to find out what IC you were running, I wasn't sure what DI was at the time - but I do now! I've been told and also found threads that the probe on my gauges for EGT is a common failure point, I've seen several with erratic temps that had a bad probe. I'm definitely hoping it's that easy!

I'm a little worried with the EGT issue to have the truck dyno'd - it's probably so quick I shouldn't be, I opted to cancel the appointment to further dive into the EGT issue before someone else looked at it. Having a really hard time letting someone touch my truck after the somewhat recent fiascos I've gone through with places keeping my vehicle for 3 weeks for parts, dropping it off the lift so on. And yes that happened to my truck recently, they dropped it off the lift or as they said "it slipped on the lift forks", I was under the dang truck looking for the reverse wire and discovered I had a new fuel tank - uh, the front tank I just got done doing the fast fill mod to didn't look like that, brand new and shiny! I showed my wife, and as I'm showing her I'm seeing the huge gash/dents in the rocker panel on the driver side - Wow.... I don't know why they didn't tell me, but I called them and "they thought someone told me" - I was not so happy, but they're fixing it.

Edit - plus the tune I ordered for the dyno didn't arrive until after I dropped the truck off, but I have it now - hopefully I can get it in for that soon (it's gonna happen!)

 

Well - good news ish - found that my up pipes are leaking, or at least the driver side is. They have been replaced before, I think that was mentioned above but I'm going to get riffraff pipes and see if that will fix it.

 

Sad news, but at least you know now.

 

honestly - I'm not sad on this... I mean I didn't want to spend the extra funds, but I've been debating the pipes for several months. I wasn't going to replace them if they weren't leaking.... well, they are!

If it fixes it, alleluia!

 

Did they put the dorman replacement pipes
in that don’t have bellows built into them? Whether your doing them or having a shop do it take some emery cloth and smooth the exhaust manifold surface over really well where the uppipes bolt on.

kc turbo recommends having someone brake stall your pickup while someone else watches for/feels for soot/air around up-pipes and manifolds.

I may have missed it, have you pressurized your intake and used soapy water to check for leaks?

I hope you have found/will find your issues because you really shouldn’t be fighting egts like you are with your setup IMO (especially empty). My 97 with 200/30s won’t go over 1150 in jelibuilt daily tune towing ~8,000 lbs up a 7 percent grade. I realize that is not THAT much weight, it’s the heaviest I’ve towed with it so it’s all I have to compare to.

 

The shop that built my transmission put the dorman pipes in - in theory they should fix it but I don't trust them after dropping my truck off the lift and such. Plus bellowed with ceramic coating sounds a lot better.

Good tips you gave, although I'm not sure how to brake stall an automatic? Is that even possible?

Yes I checked the intake side by pressurizing and soapy water.

What IC are you running?

 

Hold the brake and throttle at the same time. Also known as “brake boosting”. I think that’s what he means. But make sure it’s on jack stands or a lift before you get under there in case it gets loose

 

Not sure how you would brake stall an auto either that’s why I thought that but not sure

 

It's better if you have a leaf blower, shove it up the exhaust and with a water soap solution spray away at all pre turbo pipes.