sputtering and hard starting

ben359 · **Joined:** Thu Apr 14, 2016 10:23 pm **Posts:** 3

I am trying to diagnose some issues with an 06 CRD and have hit a wall. I had just done a head gasket on a friend's jeep and when we got it all back together it was hard starting like it had air in the fuel rail. Since we had just taken the fuel rail off I didn't think much of it. It also didn't want to idle for a while but seemed to run just fine with any bit of throttle. Again thought I just needed to get all the air out of the fuel rail. The problem never went away though and after a few dozen starts figured there was another problem. The owner also says that it seems to be low on power but I haven't driven it since I am focusing on the starting issue. It also smokes a fair amount, brake torque it and I can put out a cloud of black smoke. I started with the standard trying to find something I had failed to do when reassembling the engine. The owner did some research and decided he wanted to replace the crank and cam sensors on his own. He was smart and got real Bosch sensors but they were not the issue. I checked the timing, it's good, checked the turbo by unplugging the vacuum hose and feeling the actuating rod move. Pulled the cam housing off to make sure all the rockers were on the valves, they were. It smokes pretty good so it is getting plenty of fuel, and no fuel faulty codes. In fact the only fault it will throw is a cam sensor code and I can clear it and it will not come back until I crank and crank and crank it trying to start it. Pulled the charge air hoses off and the turbo is putting out boost and the it is pulling good air into the intake. With no fault codes I can only figure it is a mechanical issue but I haven't found any. Does anyone on here have any ideas of where to look next, anything I may have missed? Only other things done while the head was off was a weeks stage 2 and the head was decked .005. Origionaly had a 1 hole gasket, so we put a 2 hole back in.

lacabrera · **Posted:** Fri Apr 15, 2016 3:40 pm

A 2 hole gasket is about .0040inch thicker than a 1 hole. Reducing the compression ratio maybe causing your problems.

ben359 · **Joined:** Thu Apr 14, 2016 10:23 pm **Posts:** 3

I went with the 2 hole because of the thickness, the head was decked .005 so the 2 hole should get it back to about stock I would think

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flash7210 · **Posted:** Fri Apr 15, 2016 3:53 pm

I doubt its the head gasket.

Your symptoms indicate that the engine is either getting too little air or too much fuel.

You seem to have verified that the turbo is functioning, so it should be getting plenty of air.
So maybe you have a injector that is stuck open?
You can try doing a injector return flow test. All four injectors should send the same amount of fuel out their return line. If one is returning significantly less, its leaking.

lacabrera · **Posted:** Fri Apr 15, 2016 4:05 pm

ben359 wrote:

I went with the 2 hole because of the thickness, the head was decked .005 so the 2 hole should get it back to about stock I would think

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I missed that you have skimmed the head :banghead:

WWDiesel · **Posted:** Fri Apr 15, 2016 4:06 pm

Just a thought!
Does it still have a functioning FCV/EGR valves on the motor? If so the EGR may have gotten stuck in a partial open position and you are loosing boost backwards through the FCV or EGR valves back into the exhaust manifold...thus bypassing the engine.... :idea:

This could cause the symptoms (black smoke & low power) you have described.... :wink:

ben359 · **Joined:** Thu Apr 14, 2016 10:23 pm **Posts:** 3

Nope, egr deleted physically and in the computer. Also tried taking off the return lines from the injectors and they all seem to be just barely putting out any fuel.

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rankom · **Posted:** Fri Apr 15, 2016 7:40 pm

like Flash said you have an over fuel problem, there is two ways to check it . pull injectors send them to BOSCH for testing . or they can be capped one at time ., cummins does have this tool , but i didn't go to see my friends at fuel shop yet . so not sure if will work . but old fuel line with capped end should work , possibly one of injectors is a problem , also check rail fuel pressure , check exhaust manifold temperature with ER temp gun. and lastly (DONT DO IT ) but i did it . i removed turbo and exhaust manifold plugged turbo feed line with 8mm bolt and banjo copper washers , and run it SMOKE was coming out of #1

sputtering and hard starting

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