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Hello all. I have a few OBS's so I know this one is not acting right, hopefully someone can help me figure this out.
I bought a 97 powerstroke cclb zf5 about a year ago not running. Guy I bought it from said his brother started to put injectors in it but never finished. He unfortunately passed away so I could not ask why he thought it needed injectors. I have done rust repair and a few upgrades: 2000 turbo with upgraded housing and wicked wheel, EBPV delete and removed wastegate, 2002 intake spider with 2002 intake runners, FMIC, Full force stage 1.5 30% injectors, Hydra w/ jelly built tunes, CTS3, Air dog, return less fuel block (block feeds all four fuel fittings in heads) 3.5 down pipe (currently open exhaust), new exhaust manifolds, bellowed up pipes, new glow plugs.
Now the issue.... when I drive the truck it feel like it is tied to a stump and wont boost more than 1 or 2 lbs. All test drives have been on a unloaded and empty truck. I barley hear turbo when driving. I have two boost gauges, one mechanical at intake, and one digital at turbo outlet. Both read low to no boost throughout the RPM in every gear. I have checked for boost leaks and even swapped turbos with no difference. Today I noticed that the EGT go up fast to 1250 when going thru the gears hard, I have compared this truck to my 97 cclb dually with a zf6 swap and really close engine/ turbo set up, not only will my dually boost 20psi with no load behind it, but it hits hard and feels good to drive with a loud turbo whistle especially when I open up the exhaust valve. When towing 25k up a mountain at full throttle my dually EGT never top 1050 (both trucks have EGT probes in #8 manifold runner)
Any help would be appreciated! I have a MAC mentor scanner to read gauges as well as CTS3 on both trucks I have mentioned.
Last edited by templeofdsm; Jul 26, 2022 at 09:51 PM.
The first thing you need to do is flash stock tunes into your hydra and try again.
That sounds like a fueling/tuning/timing issue.
With everyone and their grandma making tunes now, its hard to even keep track of who's a good tuner or not anymore. I have never heard of who wrote your tunes, but then when I was on the elitist facebook group for 7.3's for a while, they all were "professional tuners" in there, so who knows.
But based on what you describe, it sounds like a tuning/timing/fueling issue.
There are other sensors that track into this, but if you're just ramping huge EGT's but getting no boost, that sounds more like bad tunes.
I tested truck before installing injectors. It was with stock injectors with no tuner, but had all the other mods done. I swapped injectors because I thought since truck sat for 2yrs and another 1 after I got it, I thought the injectors were stopped up or leaking
The first thing you need to do is flash stock tunes into your hydra and try again.
That sounds like a fueling/tuning/timing issue.
With everyone and their grandma making tunes now, its hard to even keep track of who's a good tuner or not anymore. I have never heard of who wrote your tunes, but then when I was on the elitist facebook group for 7.3's for a while, they all were "professional tuners" in there, so who knows.
But based on what you describe, it sounds like a tuning/timing/fueling issue.
There are other sensors that track into this, but if you're just ramping huge EGT's but getting no boost, that sounds more like bad tunes.
I would Listen to T . if it were fuel pressure the truck would fall on its face when you hit the Go pedal . The injectors only do what they are asked to do . It has nothing to do with fuel pressure if it runs . The injectors are fed from the 2 stage fuel pump . Increasing the pulse width increases fuel to the cylinders .If it stumbles or stalls I would look into fuel delivery. It sounds like the engine is running stock .PW % can be measured from the PCM with a scanner .
If you measure the FP , remember , it is measured on the return to tank. Not the pressure to injectors .
Keep in mind that the TPS may not be telling the PCM ( accurately) what you are asking for .
Fuel pressure stays at 50-55 the entire powerband in every gear, the sender is in the spliter block before it goes in to head. The system is return less, I only have one line coming from Air Dog to block Idle 3rd gear 50% throttle 2200 RPM 2nd gear 50% theottle 2k RPM
Very simple, but have you verified that the MAP line is free from debris or obstruction? If the truck sat disassembled for awhile some thing may have found a new home in the line.
jellibuilt tunes are not my favorite, but should behave better than that if installed correctly
I replaced MAP hose with a new one during upgrades. I believe the tunes are in correctly, I have another 97 that I installed same tunes on. Readings are similar to the one I'm having issues with. Also this issue happened with stock injectors and stock tunes.
Last edited by templeofdsm; Jul 28, 2022 at 07:19 AM.
Well, the first thing to do when you're having weird issues is to switch to a stock tune and troubleshoot when you've eliminated that.
Just because both trucks have the same tunes mean nothing. You're trying to eliminate all oddball factors in your control so you can troubleshoot things that make no sense.
Secondly. 55psi is low on fuel pressure.
But it wont make the truck act like you're talking about.
The only other question I could ask is what is your IPR Duty Cycle when this is happening?
What fuel pressure do you recommend? I took pics of my scanner while it was happening (which is all the time), pics are above in post, but if looks as if IPR is at 41%.
I was told I cannot go back to a stock tune once upgraded injectors are installed (I have full force stage 1.5 w/ 30% over nozzles)
Last edited by templeofdsm; Jul 28, 2022 at 07:27 AM.
Have you performed a leak test on it? You have done a lot of work on the truck. It’s possoble on of the plenums did not deal correctly and has a leak. It would be a simple way to make sure the system is tight and capable of making boost
I run my fuel at 62psi. 55 is not bad, but could be increased a little once you get the boost issue sorted out
What fuel pressure do you recommend? I took pics of my scanner while it was happening (which is all the time), pics are above in post, but if looks as if IPR is at 41%.
I was told I cannot go back to a stock tune once upgraded injectors are installed (I have full force stage 1.5 w/ 30% over nozzles)
41% is high unless you're at Wide open throttle.
You did 160/30's so If you don't have upgraded HPOP, there is your answer for your issues.
Did you upgrade the HPOP? I don't see it on your list.
Fuel pressure on these trucks, especially if you're going to run 30% nozzles, you wanna be in the low 70's high 60's.
With stock injectors, you can get away with 55. I think i have my system set at 72, but that was years ago, its probably closer to 65 now due to spring wear.
As for stock tunes in a upgraded injector truck, that's not 100% true. The injectors just do what they are told. so unless you have firehoses for injectors (200% nozzles or something like that), stock tunes will just not use the injectors efficiently.
The Fuel side is how much fuel the injector is modified to hold for a full spray, and the nozzle side is just how much faster it can get it into the cylinder on full demand.
And thinking about it, you got FullForce, so those are probably 180/30's.
This "problem" truck has 226000 miles
I have NOT upgraded my HPOP. My other truck still has stock HPOP with the same setup and pulls like a freight train for 12hr stints (205000 miles)
I have borrowed a smoke machine to do a boost leak test (to be done Saturday).
I will turn my fuel pressure up tonight (on both trucks haha)
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