...except between the intake horn and turbo. Is the intake plenum a known source for leaks? Where else?

 

The intercooler itself will sometimes develop cracks.

 

It held 15.5 psi to 14.5 psi for about a minute including the intercooler. As quickly as boost rises and falls, isn't 1 psi a minute an insignificant amount?

 

Are you sure it's not just a flakey gauge?

What kind of boost readings are you seeing at max fuel?

 

Wait, the 1 psi drop was in reference to the test. I plugged the hose at the turbo and at the intake horn (plug has a schraeder valve), pumped it up to 20 psi and blew one of the plugs out. Did it again and stopped at 15.5 psi and then checked it again about a minute later and it was 14.5 psi. So, the system is not airtight but I am trying to determine if this would cause excessive smoke. If losing 1 psi over a minute is not significant, I can go look for other causes of excessive smoke.

I don't know the history of the truck prior to 53K miles and often have wondered if the injectors are dirty, worn or otherwise causing the soot job on the quarter panel.

 

Check your Intake Manifold Gasket.

 

Did it keep losing pressure after 14.5? I would want to see how it got from 15.5 to 14.5. Your assuming it was a gradual leak...probable right but can't be sure. Could leak a lot faster at higher pressure.
Factory intercooler specs call for holding pressure at 30 psi. Cracks seem to develop most often at outflow tube...bottom on drivers side.
Did you do soapy water test to see where it's leaking?

If your boost is where it should be at heavy throttle, than your cool air system should be Ok. Think you should be at 21-23 psi.
RJ

 

that is too small a drop to wory about...unless it gets to be alot more at higher boost levels

 

what are you running for boost pressure on your gauge?

 

Boost will hit 25 psi if I hold it to the floor in 4th and run the heck out of it, maybe 26.

I plan to retest this weekend and use soapy water and more pressure.

Intake manifold gasket, em, that looks about as painful as the balljoints if I have to remove the injector lines

 

I would say your fine. I think your engine valves are to blame for your small leak down.

 

KATOOM,

I tested the air path from the turbo to the intake horn so the valves are not a factor.

 

i think your boost is fine. you most likely are wasting your time. what are you trying to accomplish?

 

243- I think your boost is about right- the soot on the quarter panel can come from a too aggressive setting of the EZ. On it's most responsive setting it will let the engine produce soot. (But this fuel will greatly help spoolup of the turbo)
If your truck doesn't make evil black clouds rolling all over the intersetion, eating up innocent bystanders I think you're quite OK- try jumpering the EZ to a lower level- instructions can be found on the Edge website: http://edgeproductsinc.com/pdf/DodgeEZInstructions.pdf

HTH

AlpineRAM

 

nitrousn,

I have been chasing the source of the excess smoke (before the EZ and totally stock) for a few months. It has gotten progressively worse. About billion people said I have a boost leak so I decided to try and find it

AlpineRAM,

With the EZ set to the most aggressive jumper, the smoke cloud was huge! Far more, double or even triple the smoke of my 99 with the 3 light Edge. I moved the jumper to the opposite end and it is much more driveable.