LBZ: Occasional low power and black smoke

psimpson

New member
May 6, 2012
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I bought a 2007 GMC Sierra Classic (95,000m) with stock Duramax LBZ motor to pull my 12,000lb trailer. All was well for a couple of months until I set out for a long trip around the Western States.
First indication of a problem was after 500 miles I got a Check Engine Light. I had this looked at by a GMC mechanic who said several fault codes were current including Vane Position Sensor problem, Turbo High Boost Pressure and Turbo Low Boost pressure. However, a couple of hours on the computer didn’t show any indication of a current problem, the codes were cleared and I carried on with my trip. A couple of days later CEL came on again. I decided to wait until I got to another GMC dealer in Arizona, who confirmed the same codes as before. By this time I was also experiencing occasional loss of power and increasing black exhaust smoke. He changed the vane position sensor and all seemed well until a couple of days later when the truck started again to lose power and create a lot of black smoke under acceleration. Motor starts and idles fine, but lacks that “diesel knock”…sounds like a gas motor revving between 1000 and 2000 rpm. But this time there was no CEL.
Despite another day at the dealership no problem could be found. Air filter and fuel filter changed, air induction system and intercooler checked for leaks, EGR valve removed and cleaned, mass airflow sensor removed and cleaned. Still black smoke and loss of power under acceleration.
Another three hours at a diesel specialist shop turned up nothing. Fuel additive was added to the tank and things seemed better for a while. However, next day loss of power and smoke again with a CEL that this time showed “excessive EGR flow” and “Park/Neutral switch Circuit Input High”.
For the last ten days or so the low power/smoke problem comes and goes with no particular pattern but seems to be getting worse, and the “excessive EGR flow” CEL appears once every few days and the “Park/Neutral switch Circuit Input High” CEL every trip.
I’m looking to this forum for anyone with similar experience with this type of problem and hopefully a resolution.
Anyone know of a good technician/shop in Montana with Duramax experience that may be able to help?
 

psimpson

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May 6, 2012
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Thanks for advice.
Both dealer and specialist checked and found no issues with turbo, and since the new vane sensor I have had no turbo-associated codes. That said of course I do still have a problem. Although the EGR valve checks out OK, I wonder if it is passing too much exhaust when the engine is working hard at and is starving the intake air of oxygen, hence the black smoke. I would have thought if the turbo boost pressure was too low I would have got a CEL.
Again the only code I get on occasion tells me that the EGR flow is high. The transmission associated code seems to have disappeared.
Unfortunatelymy route doesn't take me close to either Billings or Boise, but I can easily check Alligator in Coeur D'Alene...if I can't find someone in Butte or Missoula
 

JustinD

Plow Truck
Nov 21, 2008
2,067
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36
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Tiverton Rhode Island
Get ahold of rob or dustin or monte @ atp trucks in idaho. They are the best in your "area" alligator performance is also in idaho and is a reputable outfit. Sounds like you have codes appearing from your tcm amd ecm. If your turbo is malfunctioning your egr sensors will fault as well as they will see too much soot in the gas stream when the turbo is not developing the proper amount of boost. This all happens 3 times a second in the computer

What are you talking about????
 

chevyburnout1

Fixing it till it breaks
Aug 25, 2008
2,368
1
38
Berthoud, CO
Did the shops actually pull your intake and egr valve off to see if it was stuck open? It will read 0% on a Tech II but it may still not be sealing correctly. This could cause your smoke and lower power.
 

psimpson

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May 6, 2012
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The technician (GMC dealership) pulled the EGR valve. Although it looked quite clean he soaked it and thoroughly cleaned it. I can only presume he checked that the valve was seating properly.
I did try running the engine with the EGR motor disconnected and it still ran black smoke.
Does the EGR valve open during acceleration or when the engine is working hard? Could it just be opening too much?
Thanks
 

Odyssey25013

DF Regect
Nov 9, 2010
70
0
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CT
Your condition is identical to what would happen to me before I blocked my EGR. Under high boost I would pop open the valve and the smoke would roll. I would loose all power as well. Either the valve is not seating or the mechanism/spring (what ever the hell it is) is failing. But hey, what do I know. Does it happen under any condition or when you have your foot in it? See if the shop can fab up a blocker plate for the riser. That would completely rule out the EGR if the problem still persists.
 

psimpson

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May 6, 2012
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Thanks for that.
The technician at GMC actually suggested blocking the EGR but unfortunately didn't have the parts to do it.
Smoke will only occur when putting the engine under load...the more load the more smoke!
Sometimes it seems to get better for no reason, then pops back again.
Seems much better at high revs (over 2,000 rpm) but then the gas mileage really sucks. Currently I am getting around 15-16 on highway, 11-13 around town and 11 - 12 pulling 12,000lb.
Regards
Peter
 

psimpson

New member
May 6, 2012
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Thanks for the replies.
I used a scan tool yesterday when driving and the EGR ERR % consistently varies between -100 and +97%, and I only saw the EGR valve command open twice the whole 200 mile trip and then only 2%.
I will be taking the truck into a specialist shop in a few days, and will let you know the results.
Regards
Peter
 

psimpson

New member
May 6, 2012
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Had my truck at a diesel specialist today and they could find nothing wrong with it. They thought that there may be a tune in the computer which is delivering more fuel that really needed and suggested I get the ECM updated or reflashed at the dealership.
I guess I will do that over the next couple of days.
My EGR valve still doesn't appear to open (according to my scan tool) under any operating conditions and and while that might not be a bad thing does anyone have any ideas why that might be?
I am still planning an EGR delete kit but may wait till I've finished my trip.
 

03Tommy

New member
Jun 2, 2008
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Weston, Mo
Your condition is identical to what would happen to me before I blocked my EGR. Under high boost I would pop open the valve and the smoke would roll. I would loose all power as well. Either the valve is not seating or the mechanism/spring (what ever the hell it is) is failing. But hey, what do I know. Does it happen under any condition or when you have your foot in it? See if the shop can fab up a blocker plate for the riser. That would completely rule out the EGR if the problem still persists.

I had the same problem and just like Odyssey, blocking the EGR fixed it. Now my truck doesnt smoke at all when set on stock.
 

Hot COCOAL

May the farce be with you
Jun 9, 2012
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Peter- where are you? You just may want to(money willing) look on the forum to see if you are by a reputable performance diesel vendor sponsored by the forum. The dealer tech can only do and know so much, spend your money wisely. get an egr delete and tune while you are on the road. Do you have an egt gauge on this truck? Not to scare you, and i, by posting this hope others confirm or slap me for being stupid, black smoke = fuel, fuel=heat. You are towing 12k, which is not too heavy, but added heat while towing can cause problems, waiting till you get home, might be one mountian pass too many. Hope your trip goes and ends well.
 

psimpson

New member
May 6, 2012
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Thanks for the replies.
Can anyone advise me which brand/type would be the best EGR delete kit to use (and easiest to install) .
Can I just block the cooler outlet with a plate, or do I need to remove/refit the EGR valve (a little more difficult while on the road).
I assume I will need some other mod to prevent the CEL from coming on.
Thanks
Peter
 

Santos_LBZ

Member
Jan 2, 2014
38
0
6
California
Has anyone found a solution to this. I have a 2006 LBZ with EFI Live, modified exhaust no cat. On a cold day it will drive for like a mile then lose all power and just start pouring out black smoke. An it will be like this for about an 1/8 of an mile. Then it will clear up and not come back till next cold start up. I've changed the fuel filter, cleaned the Map sensor, changed the oil, and have gone through tanks of diesel. I've heard possibly injectors, tuning, and egr but none for sure. It drive fine after that though. I've put the tuning on stock but still does it. The boost PSI is at 1 when it happens so could it be boost related
 

tjmjjbjt

New member
Mar 4, 2016
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Lly problem

I own a 2005 gmc lly since new. I have never towed much until the last couple of years and had about 8000lbs climbing long grade on i64 out charelston wv and nearly pegged the temp guage. I was not running hard and after i slowed and truck cooled off it ran fine. I did some research and discovered the cooling problems with the lly so i ordered the lbz inlet and banks cold air intake. Immedialty after installing, the truck will intermittently loose power and emit an enoumous amount of black smoke then clear up. When this happens the truck will not allow rpms over 2000. There is no check engine light or codes. Any help is appreciated.