Ok...About 10 minutes ago I pulled the diaphram cover off my pump ('92 VE pump) to see if there was anything going on. I removed the diaphram/fuel pin & spring. I noticed there was alot of diesel fuel in there. I siphoned the fuel out to make sure the sliding pin was pushed back before reinstalling everything. I've never noticed diesel inside there before, it was usually dry. Did something happen to my pump? Could this be the reason for my low boost/high egt/excessive smoke/low power??? What happened?

As some of you know, a rag was sucked through my stock H1C turbo, everything bunched up in the intercooler, seems as nothing made it through. Replaced the turbo with a new HX35W/16cm2. Intercooler has been cleaned & cleaned again, I've triple-dipple checked for boost leaks. The truck runs fine if you baby it, but has no power if you lay into it and smokes like a train.

Mods: Starwheel In, Fuel Cone on Deepest, Power Screw In, HX35/16cm2, 4" exhaust, POD Injectors.

 

Mine's always been a little wet inside, but not a lot.

I don't know what exactly is going on with your truck, but it still sounds to me like the intake is restricted somewhere. It seems to me that the best thing to try next is to reclock the compressor and turn the intake elbow around like a non intercooled truck and run a piece of radiator hose between them to bypass the intercooler. If it runs like a rocket, there's still crap wedged in the intercooler. EGT's and boost will be higher than you're used to seeing but the power will be back if the problem is in the intercooler.

 

Hmm. I just might give that a try. I'll be pressure testing the system for leaks soon. I was just wondering if the diesel in the pump could have been my problem...darn. Guess I gotta keep on searchin'! Thanks for the info Dave.

 

BTW, don't be surprised if the piece of radiator hose ruptures when you get past 30 psi.