I just put new injectors in my truck, went with 160cc single shots from Rosewood Diesel Service thru DPP. Along with that I had my chip reburned by Tony Wildman and have been working with him on getting the settings fine tuned. I know live tuning would be the best way to get it perfected, but with him in TX and me in IA, and needing to be in the field right now, it's not possible. One problem I am having is that I'm getting excessive smoke in most all the settings. The last burn the econ and performance setting made the truck run great, but with just a little bit of a load, as in climbing a hill unloaded, it would be rolling out smoke (1600-1700rpm & ~8psi boost). Tony tuned it down a little to try and clear up the smoke, and it isn't doing it as bad, but I can still see it rolling out just in a haze almost when climbing hills.

Is this just a matter of the tunes, or would there be something else going on with my truck? With the stock injectors and a DI chip, I'd get nothing while cruising, unless I'd put my foot into it for one reason or another. But now while cruising with any sort of load it let's out smoke.

The old man has an Auto-engenuity, but we are pretty green at using it, just got it not too long ago. What should we be looking for to help address this issue?
Thanks for any input!

 

I would think air and fuel. Something is not jiving. Boost leak? Bump bump.

 

1600 RPM's, your lugging it pretty low on the rpm's. How do the EGT's look? Like Rick said, make sure you don't have a boost leak.

Also, 160 CC injectors with the stock turbo on an early 99 - your not getting enough air with the extra fuel.

 

Send me a PM and I can give you my cell # and try to walk you through some of the AE stuff that I learned from Mike and others. With an early 99 you won't be able to do as much as the newer PSD's but you can still do alot.

If you only seeing haze since the new tunes then I'm not sure I understand the isue?

 

I'm not hauling a load or pulling anything, this is just the truck itself climbing a hill (under load) as compared to coasting down a hill or cruising on flat ground.

EGT's look fine, maybe a tick high, ~800-1,000*, depending on how big of a hill.

I was just cleaning on the engine this weekend and didn't notice anything as in a boost leak, I'll take another look to double check.

I wondered if it was something as simple as not enough air, which is a great excuse to really fix the problem good and go down the road to Black Widow Diesel and get some twins. I just wish I had the money to do it. What'd be the next best step, would a different housing be enough?

 

Well, you can't detect a boost leak at idle, but you need to check & clean the boots if you think you might have a leak. Your EGT's look OK. What's the max boost you see on the econo & performance settings?

With the info you provided it does not sound like the issue is the tunes at all. You added more fuel with the larger injectors & chip, the stock turbo is not supplying enough air. AT low RPMs your gonna smoke

For the early 99 :

Beans Diesel Performance Early 99 BDP Dominator 66

"The Dominator 66 is a direct bolt on turbo. You do not need to replace your pedistal and uppipes to run this turbo.The high performance turbo upgrade will flow 1050 CFM. That is a 30% air flow increase of stock. This turbo has a 1 Year replacement warranty. That is almost 100CFM more than the Hypermax H2E turbo at less than half the price and installation time. Maximum recommended pressure is 40PSI.:

Link

99-03turbo