Black Smoke after Intercooler Install - Help! (5 Viewers)

[NJ KZJ78]

Hey gang -
Yesterday installed a front mount air to air Garrett intercooler on the 1996 KZJ78. Routed the pipes through the old horn spaces and through the back. Bought a throttle adapter for the connection to the air manifold on the passenger side and it came out really clean. Pic attached.

Everything is hooked up and clamps are tight. I start her up and she has a really rough idle and black smoke coming out of the tailpipe. This never happened since i’ve owned her. I went back and tightnes clamps, and ran soapy water over pipes to detect if any leaks. Couldnt find any.

NOTE: i have an EGR delete. Removed it last year. I do not have a manual boost controller or boost gauge installed.

I am hoping it is something simple. The only thing i can think of is the intercooler is a bit more than i need, but an oversized airflow wouldnt do it, would it?

Has anyone run into this problem? Or know enough to advise what this might be or what I should do next?

Thanks guys

 

[AVL KZJ78]

Hey gang -
Yesterday installed a front mount air to air Garrett intercooler on the 1996 KZJ78. Routed the pipes through the old horn spaces and through the back. Bought a throttle adapter for the connection to the air manifold on the passenger side and it came out really clean. Pic attached.

Everything is hooked up and clamps are tight. I start her up and she has a really rough idle and black smoke coming out of the tailpipe. This never happened since i’ve owned her. I went back and tightnes clamps, and ran soapy water over pipes to detect if any leaks. Couldnt find any.

I am hoping it is something simple. The only thing i can think of is the intercooler is a bit more than i need, but an oversized airflow wouldnt do it, would it?

Has anyone run into this problem? Or know enough to advise what this might be or what I should do next?

Thanks guys



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The presence of the intercooler circuit would not cause those symptoms, even if your IC is oversized. Any leaks at joints will only be evident under boost, not at idle or low load, and a boost leak would not cause your idle problems either. I might look into your throttle body adapter- Trundles lists it for non-egr throttle body applications, and your KZJ will Have EGR. Hard to tell from their website pics what their adapter does over the EGR butterfly in the throttle body. If it is a flat plate might it be interfering with the butterfly shaft(s) and somehow preventing the TPS from registering correctly? Also, how did you attatch the throttle linkage that used to be mounted to the crossover tube? Does your mount let the TPS shaft move correctly?