An entire LHM saga. This is going to be long to read, but I really think it illustrates perfectly how the diagnosis process can unfold and how much we can help each other on the forums. Thanks goes to Doktor A, Yahoo Sprintervan, all contributors, and especially Mike Sokol for the great summary post. The names have not been changed to protect the innocent. vic
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"Mike Sokol"
turbo hose(s) replacement
I drove back 4 hours from VA last night, and it appears I split in the turbo
hose on my 2002 with 190,000 miles. The Scan Gauge MAP only got to 17.5 PSI or
so (normally 30 MAP on hills), and LOD wouldn't go much above 80%, which of
course goes to 99% on full acceleration. I couldn't hear any hissing, but then
again it was dark and I couldn't poke around the engine too much.
I was able to fly home at 70+ MPH on the level, but big hills made me gear down
to 4th or 3rd to stop lugging the engine. Classic turbo hose failure, correct?
I'll snoop around the engine today and see if I can locate the split, but I'm
wondering if I should go ahead and replace both turbo hoses just for grins. I
think there's a short hose from the turbo to the intercooler and a longer hose
from the intercooler to the manifold, correct? Anything else I should look for
while I'm messing with this? Remember, there is no resonator to fail on a 2002,
so that's not an issue. I'm prepping for my Maryland to Texas to California to
Denver to Maryland drive next month, so anything I do now as preventative
maintenance now could save me lost road time.
Thanks for your input.... JMS
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"aquaputtana"
Mike,
With all the great advice you've given, I feel kinda funny replying to this one.
2002.... 190,000 miles.... big trip ahead in potentially hot areas of the USA...
you're going to be under, over, around, greasy replacing one hose, two, or
three. If all the hoses are OEM I'd say to change them out.
Another possible direction would be to reinforce them using black cable ties as
I did. My method is untested though so take it for what it's worth. A
description and pictures are here:
While you're poking around if you haven't changed the heater hoses I'd check
them closely too. I suppose given the generally cooler operating temperatures of
our diesel vs a gas engine they should be OK, but you never know. Hope this does
some good. vic
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James Selm
If I had a unit with 190 K I would find me a good auto electrical shop that rebuilds alternators and I would have my alternator rebuilt, replace the water pump and change the hoses and belts.
Jim 07VH 32K
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Mike Sokol
Re: [sprintervan] Re: turbo hose(s) replacement
I've read a lot about their resonator replacement, but how about http://www.riordanco.com/our_products_catalog.htm#ADAP-06 aluminum adaptor for the hose end. Is it worth the $100 for peace of mind? I'll have a chance tomorrow to really get a look at the problem, so if it's a split is on the end of the hose, perhaps the ADAP-06 is worth looking at. I had all the turbo hoses replaced about 60,000 miles ago when the turbocharger seized up, so I'm a bit miffed if a new hose let go in only 60K miles, but according to Riordanco, it's bad engineering.
JMS
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Mike Sokol
Re: [sprintervan] Re: turbo hose(s) replacement
I'll peek around some more. The alternator is original, but I think the water pump was changed out at 90,000 miles when the head was replaced. Still, that's a lot of miles, but there's no leaks, squeals, or squeaks of any kind.
The transmission fluid was changed at 85,000 miles, so perhaps it's time for that and a differential oil change as well. I have about a month to get this all done, then it's pedal down for 1,800 miles to my first stop in Texas this May.
Doktor A.... Looking for a spring project?
JMS
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rb3232 atgmail
Re: [sprintervan] Re: turbo hose(s) replacement
Hi Mike, I think that adapter is for the 6 cyl. Would it even fit the 5 cyl? Good Luck, Ross
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rb3232 atgmail
Re: [sprintervan] Re: turbo hose(s) replacement
My bad. I see there is an adapter for the 5 cyl also. Ross
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Mike Sokol
Re: [sprintervan] Re: turbo hose(s) replacement
According to their website it's for the 5 cylinder. Anyone tried one on a early Sprinter?
ADAP-06 - 2002 through early 2007, 2.7 liter 5 Cyl. Inline engine
We consider it an honor that once again Dodge dealers have asked us for a fix. This time, it is for the 2002 to 2007 2.7 liter , 5 cylinder in-line engines intercooler to intake manifold hoses which are cracking and then blowing out at the end of this hose, causing the engines to go into "limp home mode." This hose has a metal fitting "formed" onto the hose where it enters the intake manifold on the top of the driver’s side of the engine , (See photo below) which is failing causing cracks to form at the fitting (See photo below). At first, the tiny crack may cause an "occasional" limp home mode problem and then seemingly return to normal. Soon, however, this tiny crack "blows out" and becomes a big crack, putting the engine in limp home mode and ruining your workday or vacation schedule. Now you can eliminate this problem before it starts (no need to wait until the hose fails) with our ADAP-06 which solves the end cracking problems once and for all. (See Photo below) The ADAP-06 typically costs less than replacing the hose, since this hose is sold in a 3 part assembly (please see our Installation PDF below ) The ADAP-06 is being installed by many Dodge dealers and does not affect your warranty.
JMS
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aquaputtana
Re: turbo hose(s) replacement
Mike,
I haven't installed one. I also haven't seen much press about those failures on
the forums. You'd think there would be a bunch more questions and comments
surfacing if it was such a common failure. Is that where your 60,000 mile
replacement hose failed? vic
"This time, it is for the 2002 to 2007 2.7 liter , 5 cylinder in-line engines
intercooler to intake manifold hoses which are cracking and then blowing out at
the end of this hose..."
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Mike Sokol
Re: [sprintervan] Re: turbo hose(s) replacement
I'm not sure where it failed. I just felt all the turbo hoses over and under the engine, but can't see or feel any obvious cracks or holes in the hoses. However, if the tear or hole was big enough to feel without any pressure on it, it probably wouldn't have the 3 PSI of boost it made on the trip home. Do intercoolers ever fail without an obvious damage point like a deer in the grill? I don't remember reading about that on any Sprinter forum, but it's certainly possible. If no holes then perhaps its turbo vane or vane control failure like before. I'll look to see if any engine codes where thrown, but it didn't go into LHM or show any other signs of trouble. Just a MAP of 17.5 and doggy performance.
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aquaputtana
Re: turbo hose(s) replacement
Mike,
Perhaps you're in LHM and that is limiting the boost? Note question mark. I
think LHM can be set without a code being set. I KNOW LHM can be set without the
MIL aka CEL being on. There's some info here on LHM.
https://sprinter-source.com/forums/showthread.php?t=7173
vic
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Mike sokol
Re: [sprintervan] Re: turbo hose(s) replacement
You may be right. I just conferred with Doktor A and he suggests it may be a form of LHM. I pulled off the top turbo hose that feeds the intake manifold, and there's no rips, tears, or holes of any kind. Come to think of it, I don't hear the whine of the turbocharger vanes winding up much, so perhaps LHM is telling the ECU not to apply turbo boost. Makes sense. No codes are read from my Scan Gauge, but that's understandable. Need a DRB III or whatever to see ALL the codes.
Now to find the cause of LHM. The good Doktor suggests it might be fuel filter related, and since I have 20,000 miles on this filter already which was filled at a bunch of different truck stops, anything's possible. I have a spare fuel filter in my road kit, so that's a good place to start. Perhaps I'll bite the bullet and let my local FL shop read the codes for me. That might be worth the $90 they'll charge just to narrow down the possibilities.
JMS
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Reached the character limit. Continued....
