Belafonte Reboot....Ambulance to 4x4 Camper Conversion

tgreening

Expedition Leader
Put in my gauges and gauge pod today. Dual pod w/ boost and egt. Routed all the wires and plumbing. The backlights aren't wired in yet and the egt gauge needs to be hooked to keyed power, but those shouldn't be too painful. I got that massive bundle of hoses/whatever clamped away from the up pipe with I believe enough clearance but I'm not sure the dog house is going to clear my solution. If it doesn't I think a BFH will get my bracket under control.

Still need to get a piece of flex pipe to join the exhaust to the turbo down pipe temporary till I can get t to the exhaust shop, but I couldn't resist twisting the key.


Took some cranking but fired up and smoothed out after a minute. Couple issues. Water in fuel light is on, which is probably just a bad or forgotten connection. Not sure which connector that is without looking it up.

For some reason my boost gauge doesn't read. As far as I can tell it's strictly mechanical, with nothing more than a bit of tubing connecting it to the intake cap.

And the really really REALLY disappointing one. Ive got a massive fuel leak coming from somewhere I don't have a clue. I can see the connections at the fuel filter and nothing is leaking. I can see all the injectors and fuel return lines and can't see any leaking. I can see that little triangle plate that hides the fuel screw (thought that was going to be it) and can't see any leaking.

It's running to the back of the engine from under the intake somewhere up forward, from someplace I can't see, drains through a hole at the back of the engine, and then runs down the side of the block dripping out all over the starter.

The only thing I messed with fuel related was the lines at the filter. I loosened them when relocating that mess forward, but tightened them back up and I can see they aren't leaking. And I ran a new line to join the two sides of the fuel return system. It was a hose supplied by Hypermax and runs from a T fitting on the drivers side, up forward under the intake and then around the front passenger side of the intake, and then back down the passenger side to connect at the rear of the engine. I can't see that and I can't see the back bottom part of the injection pump, but I didn't do anything to the pump.

Huge bummage here because to see any of that stuff I pretty much have to yank everything back out to have any kind of access. My only simple chance is to pull out that fuel return hose from Hypermax and see f it has a split in it or something. I can access each end without removing anything else, and could probably fish a new hose back around without too much trouble, but with my luck so far I'm not holding out that it will be that simple.

But it freakin runs! Yayyyy.
 

tgreening

Expedition Leader
Fuel leak discovered! And fixed. I caught a break on this one because it turned out to be the fuel return hose that came in the Hypermax kit. It had a split in it that only really showed up when you bent the hose. What a fluke. It went straight from the box, to my bench, to installed, and I never got anywhere near it with a blade. I even got so lucky as to have a piece of 1/4' replacement fuel hose that was almost the exact length needed. I nipped a couple inches off the end and was back in business.

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And here's my bracket to wrangle all those hoses into some form that will co-exist with the exhaust up pipe.

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You can't really tell from the above pic but there is a matching curved piece on the inside of the bundle. There's a screw holding the two together and clamping all the hoses between.


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Anyway, I've got a bit of wiring to clean up, some gauges that dont seem to work anymore, and the exhaust to get replaced, and unless something is fubar that isn't evident, I should be good to go. It's taking longer than I expected but I can see the light anyway.
 

patoz

Expedition Leader
Looking good Tom!

Better to find all of those little problems while it's sitting in the shop, than out on a trail somewhere. :)
 

tgreening

Expedition Leader
It lives! Sweet Baby Jesus w/Tom Cruise Voodoo Magic, what a chore, but it's back on the road. Not sure where I sit because tuning a diesel is about 10 levels above my pay grade. If I romp in it pretty good I get a bit of black but it clears up quick. I think I'm somewhere around 2-3 flats above stock but can't swear. I had a hard time adjusting that screw and by the time I got the technique figgered I'd tweaked it in so many bits and pieces I lost track. Didn't adjust timing at all. Butt Dyno says a bit peppier, butt how much is a guess
 

patoz

Expedition Leader
:26_7_2: Now, you need to find a 'master tweaker' (no, not Miley Cyrus) and let him work his magic on it!
 

tgreening

Expedition Leader
:26_7_2: Now, you need to find a 'master tweaker' (no, not Miley Cyrus) and let him work his magic on it!


You got that right. And I think it's going to take someone versed in the idi specifically, not just "7.3". I took it to a power stroke guy for some general maintenance stuff and I could tell pretty quick I knew more about the idi than he did, and that's saying something. A 7.3 PS he's all over, a 7.3 idi is more like derrrrrrr.


Temp gauge is working. I think just idling in the gay-roge wasn't enough to make it even twitch, let alone get up to any kind of temp. On the road it's fine.

Oil pressure gauge reads less than zero. I mean like it pegs to the negative when I key on. Makes me think the sender is either open or shorted to ground. Picked up a new sender and will head out in a few to swap that in.

Boost gauge: Hmmm. I thought it wasn't reading but once on the road I do get a read, sort of. It maxed out at about 2psi when "on it", but usually reads zero, or so close to it I can't tell the difference, and I can't imagine I'm getting that little boost. EGTs run between 800-1000 on the highway depending on speed and load and I didn't think the idi could pump out those temps without some boost going on. I wouldn't think 2 psi would do it.

So, either the gauge is hosed, or the hose is hosed, or Ive got a serious case of boost leak. But again, if I wasn't actually getting the boost, could I be running those kinds of EGTs?

I'm going to check over the intake cap and the boot joining the turbo to it and see if anything jumps out.

Any thoughts anyone? And by anyone I'm guessing that's you Pat, or a couple others. Seems like I've pretty much lost the general public. :)

Maybe it's because "Belafonte Reboot" doesn't do a very good job of describing what's going on in the thread.

I wonder f I could get a Mod to edit that title to something more descriptive?
 

patoz

Expedition Leader
Tom, I wish I could help, but I know very little about the inner workings of a diesel engine, other that the basic concept. Maybe post your questions in another section that is geared more towards engines, and link back to this thread.

I believe you can edit the title yourself, by going to the first post and hit edit. Then go to 'Go Advanced' in the bottom right corner. That will open another edit page with your post, and also show the title. From there you should be able to edit and save it. Sometimes, I have been able to do this and sometimes it didn't work, no idea why. If it doesn't work, nothing will change and you won't loose anything.
 

tgreening

Expedition Leader
Tom, I wish I could help, but I know very little about the inner workings of a diesel engine, other that the basic concept. Maybe post your questions in another section that is geared more towards engines, and link back to this thread.

I believe you can edit the title yourself, by going to the first post and hit edit. Then go to 'Go Advanced' in the bottom right corner. That will open another edit page with your post, and also show the title. From there you should be able to edit and save it. Sometimes, I have been able to do this and sometimes it didn't work, no idea why. If it doesn't work, nothing will change and you won't loose anything.


I'll head over to ford-trucks.com. There's a pretty solid idi knowledge base over there.

RE the title....I did that. I went in and edited the title to something a bit more descriptive, but the title that displays in the thread list is still just Belafonte Reboot... It doesn't display the rest and I have no idea why. Some thread titles are a mile long and they display.

Just for general fyi, I hooked the boost gauge to a small compressor and gave it just a puff and the needle seems to swing just fine. I pulled the fitting off the top of the intake cap and there is almost no air that escapes. You would think there would be some significant positive pressure, even at idle with a turbo on it, yet there is essentially nothing coming out. It's almost as if there is no boost at all and I cant quite wrap my head around that.
 

patoz

Expedition Leader
Like I said, sometimes that title thing works and sometimes it doesn't. Apparently, it only works under certain circumstances, but I don't know what that would be.
 

tgreening

Expedition Leader
Input doesn't always have to be "valuable" to the project at hand. Sometimes just a simple "Dude, you are so freakin awesome to take on a project like this!" goes a long way to motivate. ;)
 

guidolyons

Addicted to Gear Oil
Is your boost gauge hooked up to the correct hose/port on the engine? You should see 5-7 psi cruising under load, and 10-15psi if you really romp on it.
 

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