About a year ago I noticed that my pickup would blow a lot of black smoke and would only build 20 PSI if I really pushed it.

I had my intercooler (plastic ends) pressure tested. Lo and behold it failed. The whole driver's side seam had split open.

I replaced it with a take off from a 2006 that has the cast ends and has been pressure tested. It seemed to fix the problem for while even though it is about half the thickness of the original intercooler.

I can hit 30 PSI but now the truck seems really laggy. it blows a lot (I mean ALOT) of black smoke on take off and between shifts, and seems very low on power. Even when I set the Smarty JR to stock.

Also, the truck does not show any codes.

Anybody have a clue what could be causing this?

Thanks in advance.

 

Check for a boost leak at one of the CAC boots. I would check them all on the high pressure side of the turbo to the intake. I wonder if you have the plastic pipe on the drivers side from the CAC to the intake?

 

This may be a stupid question, but, what does CAC stand for? I don't have the tube that runs from the intake plenum to the intake horn if that is what you are referring to.

How do I pressure test the system? Just disconnect the intercooler tube from the turbo and block it off with a plug with a Schrader valve in it to pressurize it?

Thanks again.

 

CAC = Charge Air Cooler a.k.a "intercooler"

 

Thanks!

I will check the boots to see if there is any leaking.

My main concern is the intercooler itself. As stated above, it is out of an '06 and about half the thickness of the original plastic ended intercooler.

I can maintain pressure but with the smaller intercooler I'm not sure if the flow (CFM) is adequate to allow enough airflow to keep the truck from smoking so much.

Am I up in the night about this?

Thanks again.