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Engine reduced power and smoking

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Previous post on DPF full limp mode. Car back at dealer. Had done 3 regens last week. soot at 77, said they brought back down to 21. Took car down road about 4 miles and got reduced power light again and lot of black smoke. Brought it on home and drained the diesel out and replaced with Exxon diesel. Returned to dealer. They did two more manual regens. Told them to take it out for test drive before I come pick it up. Same thing happened to tech, loaded up, sputtering, and smoking. Said getting all kinds of error codes. They are uncertain where to go next. I had put some Sea Foam in fuel when I thought it was bad fuel. Would this have caused some additional problems? The black smoke coming out exhaust is new concern, may be coincidental. At 158000 miles is it still necessary to only use dexos 5w-30 oil? Seems like oil is getting into exhaust, and I am seeing oily residue around Turbo. Think the Turbo seal may be best place to start looking? After all this soot and re-gens are all the sensors able to get cleared of soot and oil so they work correctly, or do you think I will be looking at replacement of them too?
Sorry for all questions. Not feeling too good about skill level of dealership and I am a long way from any other ones. Think they need all the help I can find.
Definitely want to get that scanguage II, and have sent inquiry in to be sure it is set up from my Cruze diesel
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View attachment 204665 WARNING: If you get symptoms I had with smoking, reduced power, sputtering, DPF full warning:
This seems to be the culprit to all the problems with DPF and Engine reduced power warning lights. Intercooler for turbo is made of plastic. It broke and also took out the Throttle body. Dealer says there is a TSB from GM on this as a known problem and they are making a modification to the part. Not sure how long it will be to get the replacement part from GM, still waiting. Not a help to me since I am way out of warranty based on mileage.
Wow! Thanks for posting about that. In 3 years on this forum, I've never seen that come up before as an issue, but obviously it is! I wonder what caused it to crack? I drive my car very hard all the time, WOT every day and in 183K miles never had an issue like this. Do you know the part number?
 

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I'll betcha this is intimately related to one of the 5 hose clamps that were brought to our attention a few months back. Loose clamps would naturally result in loss of power, CELs and movement of the parts coming into and out of the turbo . By way of illustration, I have had to tighten all of my clamps (5) at least weekly since they loosen over time. Sometimes, they loosen daily and I have to check and Retighten them. So yes GM, this is a problem ( in addition to the DEF tanks and various sensors). Let's hope they resolve all this to create a beacon of reasonableness in a sea of nuttiness!!!
 

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By way of illustration, I have had to tighten all of my clamps (5) at least weekly since they loosen over time. Sometimes, they loosen daily and I have to check and Retighten them.
Sounds like a job for Loctite. I'd sure be using that before I'd start tightening things weekly.
 

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Sounds like a job for Loctite. I'd sure be using that before I'd start tightening things weekly.

Yeah, crossed my mind!! Have tubes of it in garage.....

When I advised dealer, they refused to address it stating that it's normal for things to get loose.
 

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Yeah, crossed my mind!! Have tubes of it in garage.....

When I advised dealer, they refused to address it stating that it's normal for things to get loose.
That reminds me, I need to check mine again. I've had to tighten them a couple times, but nothing major.
 

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Hopefully, when the part comes in some day :{ I will have the part number for the new re-engineered part. Until it comes in, don't know if that along with throttle body will remedy all the problems.
Hopefully it does. Keep us posted. Did your dealership reach out to GM TAC on this? That can speed up parts delivery.
 
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Discussion Starter · #29 ·
Okay, picked up car today and is running good. The Turbo tube (intercooler) that goes from turbo to throttle body was replaced along with the throttle body. When tube broke it took out the throttle body too. Looks like the 'tube' is designed a little different but is still some type of phenolic or plastic. p/n for tube is 95472182. Mechanic said I have a build up of soot that he could see in the intake manifold that I will need to deal with soon. It had built up in the throttle body as well. May be in couple weeks will have to remove the intake manifold and have it deep vated to clean it all out. If any one knows of an easier way to get the manifolds cleaned out I would appreciate hearing from you.
 

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Okay, picked up car today and is running good. The Turbo tube (intercooler) that goes from turbo to throttle body was replaced along with the throttle body. When tube broke it took out the throttle body too. Looks like the 'tube' is designed a little different but is still some type of phenolic or plastic. p/n for tube is 95472182. Mechanic said I have a build up of soot that he could see in the intake manifold that I will need to deal with soon. It had built up in the throttle body as well. May be in couple weeks will have to remove the intake manifold and have it deep vated to clean it all out. If any one knows of an easier way to get the manifolds cleaned out I would appreciate hearing from you.
This kind of stuff plagues VWs and BMWs. There's all sorts of videos and articles about it. It was one of the main things I wondered about when I first bought my CTD - how many miles will I be able to go before I need to clean out the intake? You are the first one to post on this forum about this particular issue. I have yet to find out on my car, and I am close to 185K miles.
 

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This happened to me today at 186K miles. No CEL, but heard a sudden pop, smelled diesel fumes really strong and car ran really rough. I was able to limp it to a parking lot.Because of this thread, I immediately knew what the problem was.
Auto part Engine Vehicle
 
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That looks like a nice failure...wonder if that part number is changed since the vehicle was released. Plastic is cracking?
 

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Time for a tube diesel
 
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@gregbonat Do you have any more info on how it took out the throttle body and how it was determined it needed replaced? Mine is sitting at the dealer, but they won't be able to get to it until tomorrow.
 

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That looks like a nice failure...wonder if that part number is changed since the vehicle was released. Plastic is cracking?
I am not sure how to tell if it's a new part number. The OP hints that it may be.
 

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I am not sure how to tell if it's a new part number. The OP hints that it may be.
I sure hope so - that's the kind of failure that shouldn't be happening.
 

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Was the clamp too tight?
 

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Was the clamp too tight?
Not sure. It's not one of the clamps that I ever tightened on the other side of the engine.
 

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This has occured with our two highest mileage CTDs. 158,000 and 186,000.

@diesel this looks like something that we need to write a specific thread about and place it as a sticky.

I'm guessing we will all encounter this mechanical failure in due time. In some ways a refreshing change from emissions system faults.
 
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