A buddy of mine has a 2003 Dodge 2500 4X4 NV5600. The problem is that he was seemingly running low on power. He added the Smarty. Not a huge difference especially in the low end, and NO SMOKE! He also added the GDP 392 making sure the lift pump isn't the problem. No change. EGT's are normal, boost is normal, no codes, just low on power. We're wondering if it isn't the CP3 or injectors having problems. Oil level is good, injectors not leaking. I know the 06 and the 03 are worlds apart, but the power and smoke difference are nowhere near being close. What are possible problems? He frequents the site so if I missed something he'll chime in.

 

Leaking high pressure relief valve?

MikeyB

 

Maybe. Wouldn't you smell diesel when you popped the hood? It idles fine and runs decent. Just no power.

 

No, there's a return line. Remove the return line off the relief valve and see if fuel is dribbling out of the valve with the engine running.

MikeyB

 

Thanks. That's one possibility. Have you got any other ideas just in case that's not the problem? Also could that happen under stock conditions? He had never had any other mods until now.

 

Hmmm. Also check the FCA on the CP3 pump. Could be stuck. Take it off and shake it. If you can here it rattle it's probably ok.
Have him run a heavy dose of diesel fuel additive to make sure the tips of the injectors are clean.

And what is his max boost?

MikeyB

 

I believe he said it was 32psi, but I'm not sure. He's not running a boost elbow so I'm not 100% sure that's accurate. I figured it was either the CP3 or injectors. He's run some Howes through it. Just the normal dose though.

 

I see you watching Herkman. Am I missing anything?

 

I will 2nd the return line and relief. At least check and cancel it out. When he installed the gdp kit, make sure none of the lines are squeezed and everything routed correctly. Start at the relief valve then make sure fuel is making it back from there. Has he changed his fuel filter? I know he probably just changed it 5k ago but change it anyway. Is this truck an auto or stick? Around 30psi will be his max boost without the elbow.

 

Hey guys this is my truck and thanks for the help so far. My max boost was 22psi. When the truck is cold it seems to smoke a little more but once it warms up the black smoke turns to a gray color and there isn't as much. If i really get on the truck there's a burning electrical smell coming from the engine, but if i drive it normally it doesn't smell. Also i changed my fuel filter about 500 miles ago.

 

I know you put the gdp on, but what is lift pump pressure? I see Commander in your sig . did you get the fuel pressure kit? Where is the lift pump pressure sensor located? @ CP3? or before filter? Sure sounds fuel related., but with the smell under the hood.....could be FCA? Can you feel it clicking? It's the solenoid on the back of the CP3.

 

Quadzilla is still waiting having problems getting the harness for the commander so i haven't received the fuel pressure kit yet... So i have no clue to what my pressure is. I haven't checked the FCA yet But will as soon as i get home. Another thing i forgot to mention is most of the power loss seems to be in the lower gears. i have the smarty on SW#5 and still can't break the tires loose. if i'm on the highway i seem to have decent power.

 

22psi with the SMARTY? You need a boost elbow. I have one on mine and see 32psi with the SMARTY.
One thing to note is it's hard to build boost quickly in the lower gears of the 6spd. I cannot spin the tires (stock Michelins) on dry pavement with zero boost launches. I could only do that with the beta 4.4.

MikeyB

 

where did you get your boost elbow from?

 

You can take your elbow out of the turbo and drill and tap it for a set screw. Thats what I did at least. Mine ended up closed all the way off to get up to 40 psi max. It really only peaks there, can run 38psi suspended. Took all of about 15 minutes. Beats paying 20-30 bucks for someone else to do the same thing. Another thing to think about, is between the smarty and added fuel pressure ( if it is working right) is a better burn= less smoke.