quillaja
2004 2500 140WB high roof
I'm really at my wits end. I've been attempting to get this issue resolved for 2 years now with apparently no lasting success. POS van is a 2004 140" high roof 2500.
The basic problem is that the van inconsistently loses power, and gets almost no boost (-0.15 psi on idle, maybe up to 5-6psi when I'm flooring the pedal and the engine RPM is 3-4k). I can floor it and slowly accelerate, barely make it up easy hills, and of course there is a huge cloud of black smoke trailing behind me. When the POS isn't throwing a tantrum, it runs wonderfully--lots of power and good fuel economy.
My ultragauge has consistently said codes 0030 and 0683, O2 heater control circuit and communication with GPM code, respectively. I have never received a boost related code.
In the course of my attempt to fix this, I have done the following, in this order:
*replaced OEM turbo resonator with dorman resonator
*cleaned O2 sensor and EGR multiple times
*replaced MAP sensor, MAP temp sensor, outside air temp sensor, ambient air temp sensor.
*replaced all glow plugs and GPM with v3 as part of maintenance on failed glow plugs
*pulled and inspected engine wiring harness -- found one worn wire which i taped up, but this did nothing
*bypassed the EGR with a 2.2k ohm resistor -- seemed to fix the issue, for 2-3 months...
*replaced O2 sensor
*installed aluminum resonator eliminator, plus new turbo-side gasket and new gasket on the hose-to-intake interface
*attempted to inspect ground connections for the system--didn't see anything that looked 'bad'
*replaced EGR
*replaced wiring harness (just today).
Supposedly the turbo was replaced by a shop sometime within a year before I bought the van from the previous owner. I have some paperwork related to that, but I highly doubt that the repair warranty would be any good 2-3 years and 50k miles later.
There is no rhyme or reason to when this issue will appear. Sometimes it's on startup, sometimes in the middle of driving. Sometimes it "magically" fixes itself for days, and sometimes nothing i attempt will make the van work right. Sometimes I can drive hundreds of miles with no issues, sometimes I can't even make it down the block.
My thoughts were initially around some sort of electrical or EGR problem, due to the intermittent nature. Sometimes giggling the wiring harness would help. But after replacing both the wiring harness and EGR, as well as the O2 sensor and GPM, i don't even know what to look for.
What really gets me is that other than the wiring harness, I see no connection between the O2 sensor and the GPM. The O2 sensor, EGR, and turbo actuator are all connected electrically via the wiring harness, however. Do they all share some sort of common power source or ground? I've poured through the wiring diagrams and can't seem to see anything.
I have disconnected the turbo actuator at the upper linkage, and the arm seems to rotate freely and easily.
Recently, sometimes there seems to be diesel fuel on the either or both of the exhaust and intake sides of the engine. I don't know if this is somehow related to the cause, or if it just a result of all the unburnt fuel (from poor O2 starved combustion) going out the exhaust. This issue did not appear in the early stages of this saga.
I'm in the middle of a week-long vacation at the moment. The damned van ran wonderfully for 400 miles, but took a **** on me when I filled up on fuel. I did my usual "touch random stuff" routine and then it worked again for another 3-400 miles, until the problem happened again during driving. Somehow--i don't understand why-- I was able to get it working before I had to drive over a mountain pass by disconnecting the negative battery terminal for 30 sec. However, after that I took a nap and the damned thing has not worked since. I've smoked and floored my way hundreds of miles now -- and I'm really worried about it being like that on the way home. I'm especially worried about getting over the 2 mountain passes on the way.
I'm really really really frustrated and about ready to drive this van off a cliff. Assuming I can make it home, I think my only recourse is to take it to a mechanic in the Portland OR area, which means even more $$$ and loss of use than I've already experienced with my DIY attempts.
I don't expect an miracles, but any help figuring this out would be appreciated. I don't have wifi at my rental here in Ouray CO, so I can't check the forum very frequently while I'm on vacation. =/
Thank you,
Ben
The basic problem is that the van inconsistently loses power, and gets almost no boost (-0.15 psi on idle, maybe up to 5-6psi when I'm flooring the pedal and the engine RPM is 3-4k). I can floor it and slowly accelerate, barely make it up easy hills, and of course there is a huge cloud of black smoke trailing behind me. When the POS isn't throwing a tantrum, it runs wonderfully--lots of power and good fuel economy.
My ultragauge has consistently said codes 0030 and 0683, O2 heater control circuit and communication with GPM code, respectively. I have never received a boost related code.
In the course of my attempt to fix this, I have done the following, in this order:
*replaced OEM turbo resonator with dorman resonator
*cleaned O2 sensor and EGR multiple times
*replaced MAP sensor, MAP temp sensor, outside air temp sensor, ambient air temp sensor.
*replaced all glow plugs and GPM with v3 as part of maintenance on failed glow plugs
*pulled and inspected engine wiring harness -- found one worn wire which i taped up, but this did nothing
*bypassed the EGR with a 2.2k ohm resistor -- seemed to fix the issue, for 2-3 months...
*replaced O2 sensor
*installed aluminum resonator eliminator, plus new turbo-side gasket and new gasket on the hose-to-intake interface
*attempted to inspect ground connections for the system--didn't see anything that looked 'bad'
*replaced EGR
*replaced wiring harness (just today).
Supposedly the turbo was replaced by a shop sometime within a year before I bought the van from the previous owner. I have some paperwork related to that, but I highly doubt that the repair warranty would be any good 2-3 years and 50k miles later.
There is no rhyme or reason to when this issue will appear. Sometimes it's on startup, sometimes in the middle of driving. Sometimes it "magically" fixes itself for days, and sometimes nothing i attempt will make the van work right. Sometimes I can drive hundreds of miles with no issues, sometimes I can't even make it down the block.
My thoughts were initially around some sort of electrical or EGR problem, due to the intermittent nature. Sometimes giggling the wiring harness would help. But after replacing both the wiring harness and EGR, as well as the O2 sensor and GPM, i don't even know what to look for.
What really gets me is that other than the wiring harness, I see no connection between the O2 sensor and the GPM. The O2 sensor, EGR, and turbo actuator are all connected electrically via the wiring harness, however. Do they all share some sort of common power source or ground? I've poured through the wiring diagrams and can't seem to see anything.
I have disconnected the turbo actuator at the upper linkage, and the arm seems to rotate freely and easily.
Recently, sometimes there seems to be diesel fuel on the either or both of the exhaust and intake sides of the engine. I don't know if this is somehow related to the cause, or if it just a result of all the unburnt fuel (from poor O2 starved combustion) going out the exhaust. This issue did not appear in the early stages of this saga.
I'm in the middle of a week-long vacation at the moment. The damned van ran wonderfully for 400 miles, but took a **** on me when I filled up on fuel. I did my usual "touch random stuff" routine and then it worked again for another 3-400 miles, until the problem happened again during driving. Somehow--i don't understand why-- I was able to get it working before I had to drive over a mountain pass by disconnecting the negative battery terminal for 30 sec. However, after that I took a nap and the damned thing has not worked since. I've smoked and floored my way hundreds of miles now -- and I'm really worried about it being like that on the way home. I'm especially worried about getting over the 2 mountain passes on the way.
I'm really really really frustrated and about ready to drive this van off a cliff. Assuming I can make it home, I think my only recourse is to take it to a mechanic in the Portland OR area, which means even more $$$ and loss of use than I've already experienced with my DIY attempts.
I don't expect an miracles, but any help figuring this out would be appreciated. I don't have wifi at my rental here in Ouray CO, so I can't check the forum very frequently while I'm on vacation. =/
Thank you,
Ben