Duramax Diesels Forum Truck of the Week
  #16  
Old 01-20-2020, 09:25 AM
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Update, confirmed with tuner that the tune calls for it to turn on. I will check with a multi-meter tonight after work as well as confirming it does get hot by either pulling CAC tube or by using my IR temp gun on the housing.
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Current Rides:
1) Toy: 2005 LLY ECSB, Leather, Sunroof
-1340hp/2200ft-lbs @ ATS Diesel (06/04/19)
-Built Motor, Forced Inductions Billet ETR Gen 4 S480/96/1.10 T6 w/V2 Race Cover, F1 Diesel 275% Inj, Exergy 14mm Street Pump/LBZ CP3, Goerend AR Converter, Billet Trans, Fuelab Supply Pump/Reg, RCD & Beans Sumps, Front E-Locker, TrueTrac, Yukon 4340 Rear Shafts, Traction Bars, DHD Center Link Brace, DHD Lower Crossmember Support, Banks iDash 1.8 Monitoring System
2) DD/Tow Rig: 2002 LB7 CCSB, Leather, Loaded
-Cast S475/96/1.10 T6 Over Stock IHI, FASS 150,4" Exhaust, RCD Sump, PPE Sleeves, DHD Centerlink Brace, DHD Lower Crossmember Support, "Budget" Motor, Big Oil Cooling, Banks iDash 1.8 Monitoring System
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  #17  
Old 01-20-2020, 08:22 PM
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Checked resistances and voltages tonight once the truck cooled down enough to turn the intake air heater on, below is what my Fluke told me. Based on these resistances and voltage drops to the glow plugs I’m thinking it’s time to rewire those circuits? ~2.7v drop seems quite excessive. My other thought is maybe the controller cannot handle the current demand but that wouldn't necessarily be true since the stud that feeds the glow plugs is higher than glow plug voltage but significantly less than supply voltage.


Voltages:

Intake heater circuit at glow plug controller: 10.6v
Intake heater circuit at heater: 10.56v
At glow plugs (each bank): 8.26v
At stud/lug for glow plugs on the controller 9.6v
Supply: 12.26v key off, 10.9v key on


Resistances:

Driver side (#6) to lug on gp controller: 6.6-7.6ohm
Passenger side (#5 & #7) to lug on gp controller: 7-15ohm
Intake heater circuit to lug on gp controller: 1.5ohm
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K&D Service Inc
Call or Text: 906-284-0962
Providing a "one-stop-shop" for all of your automotive needs!

Current Rides:
1) Toy: 2005 LLY ECSB, Leather, Sunroof
-1340hp/2200ft-lbs @ ATS Diesel (06/04/19)
-Built Motor, Forced Inductions Billet ETR Gen 4 S480/96/1.10 T6 w/V2 Race Cover, F1 Diesel 275% Inj, Exergy 14mm Street Pump/LBZ CP3, Goerend AR Converter, Billet Trans, Fuelab Supply Pump/Reg, RCD & Beans Sumps, Front E-Locker, TrueTrac, Yukon 4340 Rear Shafts, Traction Bars, DHD Center Link Brace, DHD Lower Crossmember Support, Banks iDash 1.8 Monitoring System
2) DD/Tow Rig: 2002 LB7 CCSB, Leather, Loaded
-Cast S475/96/1.10 T6 Over Stock IHI, FASS 150,4" Exhaust, RCD Sump, PPE Sleeves, DHD Centerlink Brace, DHD Lower Crossmember Support, "Budget" Motor, Big Oil Cooling, Banks iDash 1.8 Monitoring System

Last edited by Bdsankey; 01-21-2020 at 06:00 AM. Reason: Added info
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  #18  
Old 01-21-2020, 07:26 AM
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More info, unless I remember incorrectly I have both wires with barrel clips going to the rear terminal. Looking at replacement controllers they have one on each terminal. When I did injectors I just undid the wires at the controller instead of risking breaking the aged plastic. Looks like I have another data point to check out tonight. This is how it was wired from the PO but I had never had it in winter until March 2019 (parked it for quite awhile until I made putting injectors in it a priority then parked it from August to January since I try not to drive it in the salt but it became a necessity).

I do have the intake heater on the front terminal. I'll move the smaller barrel connector wire to the front terminal tonight (based on the images from RockAuto). Truck is a 2002 Federal emissions.
Attached Images
File Type: jpg GP-Wiring.jpg (31.7 KB, 19 views)
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K&D Service Inc
Call or Text: 906-284-0962
Providing a "one-stop-shop" for all of your automotive needs!

Current Rides:
1) Toy: 2005 LLY ECSB, Leather, Sunroof
-1340hp/2200ft-lbs @ ATS Diesel (06/04/19)
-Built Motor, Forced Inductions Billet ETR Gen 4 S480/96/1.10 T6 w/V2 Race Cover, F1 Diesel 275% Inj, Exergy 14mm Street Pump/LBZ CP3, Goerend AR Converter, Billet Trans, Fuelab Supply Pump/Reg, RCD & Beans Sumps, Front E-Locker, TrueTrac, Yukon 4340 Rear Shafts, Traction Bars, DHD Center Link Brace, DHD Lower Crossmember Support, Banks iDash 1.8 Monitoring System
2) DD/Tow Rig: 2002 LB7 CCSB, Leather, Loaded
-Cast S475/96/1.10 T6 Over Stock IHI, FASS 150,4" Exhaust, RCD Sump, PPE Sleeves, DHD Centerlink Brace, DHD Lower Crossmember Support, "Budget" Motor, Big Oil Cooling, Banks iDash 1.8 Monitoring System

Last edited by Bdsankey; 01-21-2020 at 07:35 AM.
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  #19  
Old 01-21-2020, 09:38 PM
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Those 2 blue wires are feedback to the ECM. One is used to monitor glow plug voltage, the other is for the IAH voltage, both downstream from the relay. If you had both connected to the same terminal, it seems like the ECM may throw a code?

P0380 for the glow plugs, P0540/P0543 for the IAH.
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  #20  
Old 01-21-2020, 09:47 PM
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Quote:
Originally Posted by Bdsankey View Post
Checked resistances and voltages tonight once the truck cooled down enough to turn the intake air heater on, below is what my Fluke told me. Based on these resistances and voltage drops to the glow plugs Iím thinking itís time to rewire those circuits? ~2.7v drop seems quite excessive. My other thought is maybe the controller cannot handle the current demand but that wouldn't necessarily be true since the stud that feeds the glow plugs is higher than glow plug voltage but significantly less than supply voltage.


Voltages:

Intake heater circuit at glow plug controller: 10.6v
Intake heater circuit at heater: 10.56v
At glow plugs (each bank): 8.26v
At stud/lug for glow plugs on the controller 9.6v
Supply: 12.26v key off, 10.9v key on


Resistances:

Driver side (#6) to lug on gp controller: 6.6-7.6ohm
Passenger side (#5 & #7) to lug on gp controller: 7-15ohm
Intake heater circuit to lug on gp controller: 1.5ohm
Voltage seems low for just having the key on, as well as voltage to the glow plugs. I agree that the voltage drop across the glow plug wiring seems excessive too
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  #21  
Old 01-22-2020, 04:43 AM
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Quote:
Originally Posted by dndj View Post
Those 2 blue wires are feedback to the ECM. One is used to monitor glow plug voltage, the other is for the IAH voltage, both downstream from the relay. If you had both connected to the same terminal, it seems like the ECM may throw a code?

P0380 for the glow plugs, P0540/P0543 for the IAH.
It’s not setting a CEL, I’ll scan for codes with the V2 this morning to make sure.


Quote:
Originally Posted by PureHybrid View Post
Voltage seems low for just having the key on, as well as voltage to the glow plugs. I agree that the voltage drop across the glow plug wiring seems excessive too
Batteries are brand new, like I put them in on 1/11/2020 and used Interstate MTP-78DT. Keep in mind, they key on engine off voltage is with a FASS/glow plugs/intake air heater/HVAC/radio all running. I’m going to replace the controller and wiring to the flow plug rails. The bars between each glow plug don’t appear to be touching anything they shouldn’t leading me to believe one of the wires may have a potential short or got kinked/pinched etc since the passenger side resistance swings quite a bit.
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K&D Service Inc
Call or Text: 906-284-0962
Providing a "one-stop-shop" for all of your automotive needs!

Current Rides:
1) Toy: 2005 LLY ECSB, Leather, Sunroof
-1340hp/2200ft-lbs @ ATS Diesel (06/04/19)
-Built Motor, Forced Inductions Billet ETR Gen 4 S480/96/1.10 T6 w/V2 Race Cover, F1 Diesel 275% Inj, Exergy 14mm Street Pump/LBZ CP3, Goerend AR Converter, Billet Trans, Fuelab Supply Pump/Reg, RCD & Beans Sumps, Front E-Locker, TrueTrac, Yukon 4340 Rear Shafts, Traction Bars, DHD Center Link Brace, DHD Lower Crossmember Support, Banks iDash 1.8 Monitoring System
2) DD/Tow Rig: 2002 LB7 CCSB, Leather, Loaded
-Cast S475/96/1.10 T6 Over Stock IHI, FASS 150,4" Exhaust, RCD Sump, PPE Sleeves, DHD Centerlink Brace, DHD Lower Crossmember Support, "Budget" Motor, Big Oil Cooling, Banks iDash 1.8 Monitoring System

Last edited by Bdsankey; 01-22-2020 at 07:10 AM.
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  #22  
Old 01-22-2020, 08:29 PM
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Not as cold as you, about 50 degrees outside, but here's what I measured on my 03 with my trusty Fluke meter for comparison. My truck batteries are 4 years old.

Intake heater circuit at heater: 10.3v
At 12v input stud/lug for glow plug/IAH controller (relays) 10.6v
At output stud/lug for glow plugs, on the controller 10.3v
At glow plugs, driver's side, measured @ #6: 10.0v
Supply: 12.26v key off, 11.0v key on

Supply voltages look nearly identical key on/key off. The biggest difference I see is the voltage on your glow plug rail is significantly lower.
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  #23  
Old 01-23-2020, 07:54 AM
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Quote:
Originally Posted by dndj View Post
Not as cold as you, about 50 degrees outside, but here's what I measured on my 03 with my trusty Fluke meter for comparison. My truck batteries are 4 years old.

Intake heater circuit at heater: 10.3v
At 12v input stud/lug for glow plug/IAH controller (relays) 10.6v
At output stud/lug for glow plugs, on the controller 10.3v
At glow plugs, driver's side, measured @ #6: 10.0v
Supply: 12.26v key off, 11.0v key on

Supply voltages look nearly identical key on/key off. The biggest difference I see is the voltage on your glow plug rail is significantly lower.
I'm thinking that is the problem. It doesn't help that on the way to work the truck decided to develop a rod knock.
__________________
K&D Service Inc
Call or Text: 906-284-0962
Providing a "one-stop-shop" for all of your automotive needs!

Current Rides:
1) Toy: 2005 LLY ECSB, Leather, Sunroof
-1340hp/2200ft-lbs @ ATS Diesel (06/04/19)
-Built Motor, Forced Inductions Billet ETR Gen 4 S480/96/1.10 T6 w/V2 Race Cover, F1 Diesel 275% Inj, Exergy 14mm Street Pump/LBZ CP3, Goerend AR Converter, Billet Trans, Fuelab Supply Pump/Reg, RCD & Beans Sumps, Front E-Locker, TrueTrac, Yukon 4340 Rear Shafts, Traction Bars, DHD Center Link Brace, DHD Lower Crossmember Support, Banks iDash 1.8 Monitoring System
2) DD/Tow Rig: 2002 LB7 CCSB, Leather, Loaded
-Cast S475/96/1.10 T6 Over Stock IHI, FASS 150,4" Exhaust, RCD Sump, PPE Sleeves, DHD Centerlink Brace, DHD Lower Crossmember Support, "Budget" Motor, Big Oil Cooling, Banks iDash 1.8 Monitoring System
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  #24  
Old 01-23-2020, 08:57 AM
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Quote:
Originally Posted by Bdsankey View Post
I'm thinking that is the problem. It doesn't help that on the way to work the truck decided to develop a rod knock.
Bummer. That doesn't sound good.

I should have also mentioned my truck has 140k on it and glow plugs haven't been touched. I am not sure of the expected life on these, but maybe it's possible I have a few out, and thus my 10.0v voltage doesn't pull down as low as your 8.26v.
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  #25  
Old 01-23-2020, 09:09 AM
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Quote:
Originally Posted by dndj View Post
Bummer. That doesn't sound good.

I should have also mentioned my truck has 140k on it and glow plugs haven't been touched. I am not sure of the expected life on these, but maybe it's possible I have a few out, and thus my 10.0v voltage doesn't pull down as low as your 8.26v.
I'm betting my voltage is from a weak controller OR a partially compromised wire causing a partial short eating up some of that voltage. I knew the motor was tired but didn't think it was that bad. Had ~15-20psi at idle hot and ~25-30 at 2k rpm so it was low but guess it decided to just randomly let go. I don't think its injectors as those are genuine new (not reman) Bosch put in early 2019 and only have around 10k on them since always supplied by a FASS with regular filter maintenance. It isn't a broken crank as the truck still charges. I'll check the balancer tonight and see if it is wobbly but it idles smooth. As soon as you increase RPM there is a loud knocking sound coming from the engine bay that distinctively sounds like bearing failure.


I have all the parts to rebuild it as long as nothing got hurt (crank) besides the top end gaskets and rings. I'm hoping to just put new rings/bearings/oil pump/oil cooler etc in and not have to bore it (hoping a ball hone does the job).
__________________
K&D Service Inc
Call or Text: 906-284-0962
Providing a "one-stop-shop" for all of your automotive needs!

Current Rides:
1) Toy: 2005 LLY ECSB, Leather, Sunroof
-1340hp/2200ft-lbs @ ATS Diesel (06/04/19)
-Built Motor, Forced Inductions Billet ETR Gen 4 S480/96/1.10 T6 w/V2 Race Cover, F1 Diesel 275% Inj, Exergy 14mm Street Pump/LBZ CP3, Goerend AR Converter, Billet Trans, Fuelab Supply Pump/Reg, RCD & Beans Sumps, Front E-Locker, TrueTrac, Yukon 4340 Rear Shafts, Traction Bars, DHD Center Link Brace, DHD Lower Crossmember Support, Banks iDash 1.8 Monitoring System
2) DD/Tow Rig: 2002 LB7 CCSB, Leather, Loaded
-Cast S475/96/1.10 T6 Over Stock IHI, FASS 150,4" Exhaust, RCD Sump, PPE Sleeves, DHD Centerlink Brace, DHD Lower Crossmember Support, "Budget" Motor, Big Oil Cooling, Banks iDash 1.8 Monitoring System
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