WTF!?!? Overboost problem again!

Quick briefing on problem.

01' 75K on it, airaid intake, 4" magna flow. Throwing overboost code while towing on average highway grades. Does not do it on every grade, and the grade does net seem to matter (steepness).

Dealer says it is the aftermarket stuff and wants to put it back to stock, and that "will solve all my problems". I argue that I bought the truck with $1K worth of better equipment and I want it. Plus it gets more power and better fuel economy. Chevy/dealership STRONGLY disagrees.

Many members here have said on 02' reflash would work, and has worked for some. The dealership says this is impossible unless they could find the exact truck in an 02' and give the computer it's VIN. They say all trucks are different in minor ways and a reflash needs to be specific to a VIN. They say they plug the truck in and it "talks" to Detroit and they do all the reflash. Is this true or B.S.?

I know I donot have the only truck with this problem, there have got to be hundreds if not thousands that have done these specific upgrades (intake,exhaust), why are they not having problems? Or how did they fix them? I know JK will say come talk to me and I will make all of your problems dissapear! Thanks JK! I do want to do a custom tune from JK but just dont have the cash right now. Plus now it's getting to be a pissing contest between myself and the dealership.

Thanks for any help! Shed

Your dealer is mostly correct. By installing the intake and exhaust, you've unlocked some of the engine's potential. Problem is, the computer isn't seeing what it wants to see, and throws a fit. If you install the OEM intake/exhaust, the overboost will very likely go away, along with your little power/economy boost, but the PCM will be happy again.

Your dealer is also correct, in that HE cannot reflash the PCM w/o a VIN from a near exact 02 truck. HE cannot. That doesn't mean you can't clone the PCM of a like truck, then enable/disable the effected/different features. Ideally, JK's (or perhaps others) reprogram would be best. If he says he has the answer, believe it. It's also more likely to cost you much less to go with an aftermarket programmer, like JK, than to deal with the dealer's shop labor rates. The bottom line with this is your dealer is not really the one to do the mods you need. There are some dealers more eager to accomodate these issues, but GM's general policy it to stay away from them. Anything other than OEM is on the independent dealer, and GM won't support them. Most dealers won't discuss the matter as far as yours did.

Dmaxmaverick,
I agree, I think I'm just reaching for something that is'nt there. I agree JK is the best option. Tried to get Chevy rep to admit I made the truck better/more efficient but he refused. I think that's what got me all worked up! Thanks for the reply. If anyone else has 2 cents they want to put in please feel free! Thanks again, shed

Back in 2001 GM had a reflash for some small problems like cruise control down shifting to easy , engine codes caused by the block heater and a warm start and over boost codes. if your truck has this update done you poss have a differnt problem. Do you know how high the boost gets on your truck , my 2001 with a 4" full exhaust and a drop in aircleaner with my hot juice set on level 4 would easy hit 32~34 lbs of boost. Never once did it set a overboost code and it spent most of its time at 0-1000' above sealevel ( some time I would tow into the mountains that crested right around 3500'. If you dont have a boost gauge that is accurate to 40 lbs its hard to say where to start but I would look very close at the wastegate first.

When we start using add-on performance enhancers, you need to understand how they make more power, and still keep the PCM happy. Most of the time, they make sure the PCM sees what it wants to. In the case of the Edge, the PCM is lied to, which results in more fuel, boost, and adjusted timing, but the PCM is oblivious to it. Your boost may actually be over what is acceptible by the PCM, but it doesn't see it, so it's happy. With OEM programming and no add-on enhancer (like Edge), an overboost can mean several things, some wrong, some not. This is also the problem with damaged engines. If the PCM can't see a problem, it has no way to counter an issue that can cause damage. This is why it is so important to have gages with mods so we can be the watchers. Remember, the PCM assumes all the equipment is still OEM.

Shed,

I am a technician at a GMC dealer in Portland, Oregon and I am more than willing to give you all the info you need (all that I am capable of). So let's work together on this. First off, what is your vehicle VIN? If I have the VIN I may be able to tell you what calibrations are available for your truck. Second of all if you take the vehicle back to the dealer and tell them that the engine "surges" at times, they may reflash the pcm. I do believe that in 2001 there was software to address that complaint. I reflashed many DMAX pcms for the surge complaint. The software usually didn't fix anything, I usually ended up having to replace the regulator. :)

The other issue here is that your truck is out of the 5 year 100000 mile warranty and will probably be out of the 7 year 200000 mile injector warranty?

Here SHED:

I just did a SPS programming update on a 2001 pickup today after replacing the injectors. Here is the bulletin. Show it to your dealer.

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Subject: 6.6L LB7 Duramax Diesel DTC P0234, P0106 #PI00036 - (06/18/2002)



Models: .




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When servicing the vehicle with the VIN you entered, the following diagnosis might be helpful if the vehicle exhibits the described symptoms.

Condition/Concern:
DTCs P0234 and or P0106

Recommendation/Instructions:
Verify all intake air duct work clamps are securely clamped and correctly positioned. Refer to SI documents 697123 and 741002 for locations on clamps and duct work.
Verify connection to baro sensor is good. If P0106 is reoccuring, replace baro sensor.
If all duct work is secure, and the trouble tree for the associated DTC leads to NTF, and if the DTC is set only when a load is placed on the engine, reflash the PCM with calibration 15076144 or higher.
Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. This diagnostic approach was developed for the vehicle with the VIN you entered and should not be automatically be used for other vehicles with similar symptoms.
:cool:

Duramaster,
Thank you for any expertise you can provide! I'm kinda new so bear with me. The VIN is 1gchk29121e289570. So what does this bulletin say in Laymans terms? And what would the surging problem have to do with overboost and limp mode? The truck runs great while not pulling, and then can run great but OCCASIONALLY has this overboost problem. I just pulled this past weekend and did not have 1 problem. I was pulling on extremely flat terrain, temps in the low 80's, no wind. And I was'nt hammering the old girl, just running 65mph. The truck has 76K miles on it now, it had injectors at 65k is what the dealership told me. That would have been immediately before I purchased it. Is there a record of any problems/service performed on this truck? How did the dealership know about the injectors? Wonder if they did the work. Sorry to ramble, just baffled and feel like something is weird here, and I'm obviously not knowledgeable enough to know which way is up! Thank yo very much for your help! Shed:)

Call John Kennedy at www.kennedydiesel.com .


My guess is you have two issues:

1) Need '02 programming; (Random overboost codes)
2) Need new fuel pressure regulator. (Surge)

If you don't run FPPF or another quality fuel additive, you should start and change fuel filters every 10K.

Mark, I know, I have talked with JK via e-mail, and he has assured me that he can cure all my trucks problems with his custom tune. And I believe him! I just was trying to find something for now without shelling out the big bucks which I don't have right now. I'm using Amsoil diesel concentrate, and am getting ready to replace the filter. Should be fun, a mechanical idiot messing with a Dmax engine! I feel confident that you gentlemen have prepared me for this though! Thanks Mark! Shed

I had a chronic overboost code problem with my 03. It turned out to be loose intake clamps. Once all the clamps were retorqued the problem went away. It only happened under load with the fiver hooked up otherwise not an issue.
Denny

Thanks Denny, first I've heard of that, but I will definately check that out!

Hey Shed,

Here is the software history for the vehicle. Now what I can't tell you is how current your software is. This just shows the software progression for the supplied VIN. The most recent calibration will be at the top of each section. You will have to have the dealership hook up the Tech 2 and go through the steps to find out how current your software is.

:)
VIN: 1GCHK29121E289570
Controller: PCM/VCM Powertrain/Vehicle Control Module




Calibration History for: Operating system
Part Number CVN Bulletin # Description
15188873 N/A - New software to correct false setting of DTCS P0116 and P0181.
15097100 N/A - New software to improve generic scan tool operation
15063376 N/A - New calibration to address driveability and emissions compliance issues
9393838 N/A - Operating system


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Calibration History for: Engine
Part Number CVN Bulletin # Description
15097103 0000812F 210730034 New calibration to address excessive shifting with cruise on and idle surge
15082517 00006CCF - New calibration to reduce roughness on hard acceleration above 2600 RPM
15076142 000052D3 - Calibration to correct false trouble codes and a misfire condition. Also addresses P0234 diagnostic codes.
15072655 000023B8 - New calibration to address driveability concerns while in tow/haul mode
15063385 00009119 - New calibration to address driveability and emissions compliance issues
9375153 00008FBC - Engine calibration


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Calibration History for: Engine diagnostic
Part Number CVN Bulletin # Description
15097105 0000A513 - New calibration to correct setting of false DTC P0236
15082519 00008FCC - New calibration to address the throttle pedal progression issue at 0 percent
15076144 0000A75E - Calibration to correct false trouble codes and a misfire condition. Also addresses P0234 diagnostic codes.
15063387 00008DF1 - New calibration to address driveability and emissions compliance issues
9375180 0000C6D9 - Engine diagnostic calibration


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Calibration History for: Fuel system
Part Number CVN Bulletin # Description
15189542 00006BD9 - New calibration to correct false setting of DTCS P0116 AND P0181
15063379 00004F59 - New calibration to address driveability and emissions compliance issues
9375210 00003FE0 - Fuel system calibration


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Calibration History for: System
Part Number CVN Bulletin # Description
15097111 00001429 - New calibration for improved power in reverse when in 4WD low
15082525 000010CA - New calibration to revise the oil life calibration from 5000 to 7500
15063393 000087CB - New calibration to address driveability and emissions compliance issues
9375220 000073F3 - System calibration


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Calibration History for: Speedometer
Part Number CVN Bulletin # Description
15063401 000053E8 - New calibration to address driveability and emissions compliance issues
9375243 00009B57 - Speedometer calibration


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Print Close

Have you owned the truck since new? I ran A GM VIS and found that at about 32000 miles in September 2002 the ECM was replaced.

Duramaster,
Interesting, what I understand of it. Or think I understand... I bought the truck with 65K on it, in July of 06'. Very happy with it with this small exception. I pulled again this week and again had no issues with the over boost. I don't have a clue what the heck is going on. I really do appriciate you taking the time to check the history for me! Can you tell me what some of this stuff is that you sent me? Anything major? Anything I should be worried about? Thanks! Shed

Shed:

Here is the warranty claim history of your truck:::


VIN : 1GCHK29121E289570
CLAIM HISTORY
Repair Order Date : 09/14/2005 Repair Order Number : 036231 Odometer Reading : 64509 miles
Serviced By : TRAGER MOTOR COMPANY
PO BOX 319
OSCEOLA, IA 50213-0319
(641) 342-2134 Selling Source : 13 - CHEVROLET
Site Code : 18730
Business Associate Code : 191897
Cycle Date Cycle Nbr Case Type Labor Operation Part Comments
09/16/2005 622 01 F Z7200 - CORPORATE PARTS RETURN REIMBURSEMENT N/A N

Repair Order Date : 08/25/2005 Repair Order Number : 036001 Odometer Reading : 64509 miles
Serviced By : TRAGER MOTOR COMPANY
PO BOX 319
OSCEOLA, IA 50213-0319
(641) 342-2134 Selling Source : 13 - CHEVROLET
Site Code : 18730
Business Associate Code : 191897
Cycle Date Cycle Nbr Case Type Labor Operation Part Comments
09/02/2005 618 01 # V1380 - 05546 - REPLACE FUEL FILTER 97385488 - FILTER N
09/02/2005 618 02 # T5603 - 04039 - REPLACE ALL 8 FUEL INJECTORS - REFER TO TSB 04-06- 97729095 - INJKT REM N

Repair Order Date : 11/03/2004 Repair Order Number : 032402 Odometer Reading : 62071 miles
Serviced By : TRAGER MOTOR COMPANY
PO BOX 319
OSCEOLA, IA 50213-0319
(641) 342-2134 Selling Source : 13 - CHEVROLET
Site Code : 18730
Business Associate Code : 191897
Cycle Date Cycle Nbr Case Type Labor Operation Part Comments
11/05/2004 532 01 # V1242 - 04007 - INSPECT AND REPLACE TAILGATE SUPPORT CABLES INC. H 88980509 - CBL-E/GAT N

Repair Order Date : 03/04/2003 Repair Order Number : 024738 Odometer Reading : 53934 miles
Serviced By : TRAGER MOTOR COMPANY
PO BOX 319
OSCEOLA, IA 50213-0319
(641) 342-2134 Selling Source : 13 - CHEVROLET
Site Code : 18730
Business Associate Code : 191897
Cycle Date Cycle Nbr Case Type Labor Operation Part Comments
03/18/2003 361 01 # V0755 - CHANGE PIN LOCATION N/A N

Repair Order Date : 09/27/2002 Repair Order Number : 023331 Odometer Reading : 32658 miles
Serviced By : TRAGER MOTOR COMPANY
PO BOX 319
OSCEOLA, IA 50213-0319
(641) 342-2134 Selling Source : 13 - CHEVROLET
Site Code : 18730
Business Associate Code : 191897
Cycle Date Cycle Nbr Case Type Labor Operation Part Comments
10/04/2002 314 01 # J6360 - POWERTRAIN CONTROL MODULE REPLACEMENT 09388505 - MODULE N

Repair Order Date : 03/01/2002 Repair Order Number : 021544 Odometer Reading : 16573 miles
Serviced By : QUERREY MOTORS, INC.
PO BOX 319
OSCEOLA, IA 50213-0319
(641) 342-2134 Selling Source : 13 - CHEVROLET
Site Code : 18729
Business Associate Code : 111978
Cycle Date Cycle Nbr Case Type Labor Operation Part Comments
05/03/2002 270 01 # J5000 - AIR CLEANER - REPLACE 25345138 - CLEANER N
05/03/2002 270 02 # J6355 - POWERTRAIN CONTROL MODULE TRANSMISSION REPROGRAMMING WITH N/A N

Repair Order Date : 12/17/2001 Repair Order Number : 098844 Odometer Reading : 11764 miles
Serviced By : HOLMES CHEVROLET INC.
2913 NORTH JEFFERSON WAY
INDIANOLA, IA 50125-9492
(515) 961-8131 Selling Source : 13 - CHEVROLET
Site Code : 18070
Business Associate Code : 183982
Cycle Date Cycle Nbr Case Type Labor Operation Part Comments
12/25/2001 233 01 # N6606 - WIRING AND/OR CONNECTOR - FUEL SYSTEM - REPAIR OR REPLACE N/A N

Repair Order Date : 07/30/2001 Repair Order Number : 263964 Odometer Reading : 387 miles
Serviced By : RATIGAN MOTOR CENTER, INC.
PO BOX 386
MISSOURI VALLEY, IA 51555-0386
(712) 642-4131 Selling Source : 13 - CHEVROLET
Site Code : 05736
Business Associate Code : 111968
Cycle Date Cycle Nbr Case Type Labor Operation Part Comments
08/03/2001 192 01 # B4301 - HANDLE AND REMOTE CONTROL, FRONT DOOR LOCK - LEFT - R&R OR N/A N

Repair Order Date : 04/04/2001 Repair Order Number : A89570 Odometer Reading : 0 miles
Serviced By : CLASSIC CHEVROLET-CADILLAC
1010 34TH AVE
COUNCIL BLUFFS, IA 51501-8076
(712) 366-2541 Selling Source : 13 - CHEVROLET
Site Code : 05630
Business Associate Code : 111942
Cycle Date Cycle Nbr Case Type Labor Operation Part Comments
04/10/2001 159 01 I Z7000 - PRE-DELIVERY INSPECTION - BASE TIME N/A N

As far as the software goes for your truck, you will have to take the truck to your dealer and have them see how current the software is. To do this, they need to go through the SPS process. Not a big deal. Any DMAX tech can do this with their eyes closed. :)

Duramaster, Thank you again! You have been a huge help!! Anyway you might want to move to the midwest say central Iowa and work at a dealership???? I'll have them check out the SPS. Again thank you, I really do appriciate it.
Shed

No problem! :D