Rocket Man's 02 Denali Build Thread AKA "THE BEAST"

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95escahoe

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It's not good news. It's barely running, something's wrong. I'm torn up from all the work on it and I was supposed to go back to work tomorrow. I don't know what's wrong but I don't have a good feeling. There was an extra set of weird intake gaskets in the kit but nothing in the instructions about them. Everybody was closed yesterday when I installed the lower manifold so there was nobody to answer questions. I didn't see how they would work so I thought they were added by mistake, like they also added fuel injector connectors by mistake. Today BlackBear finally got back to me and they sent an "LS Addendum on intake gaskets" that showed them being used, and being held in place with some adhesive shit while the manifold is lowered. I then called Whipple and they said I should be fine , they've been using just the O-rings they included without a problem. Then I went out and finished up the install and tried to start it. Those gaskets are about 8 hours of work to replace because the SC has to come off first. I'm sick, and don't know if I have massive intake manifold leaks or if it's something else. I did notice a bit ago there is a hose connection on top of the throttle body so if someone can go look to see where that goes, please let me know. I think it might have gone to the passenger side valve cover. But hey, I just talked to work in the middle of typing this and decided to take this entire week off. F it, I'll figure this out if it kills me. I'll just have to get around on this old bike I have for awhile.

View attachment 80771

View attachment 80772

Damn that sucks, this hose is on top of the TB? I can look in the morning I've got my engine cover off atm, I take it's a factory hose?


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Rocket Man

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Damn that sucks, this hose is on top of the TB? I can look in the morning I've got my engine cover off atm, I take it's a factory hose?


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Yep. I think it went to the passenger side valve cover. The Whipple instructions called that the PCV filter line and had me connect it from the valve cover to the air inlet tube. My Spectre CAI didn't have a hose connected to it so maybe that explains it. The instructions are for a 2003 since they don't make a kit for a 2002 since they were mostly DBC instead of DBW like mine is so some parts are different. On another note, Justin just got back to me and said code P0200 is my problem, one or more of my fuel injectors isn't connected. I'll have a look tomorrow, it's getting late and I'm beat. Some of those are really hard to get to now.

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95escahoe

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Yep. I think it went to the passenger side valve cover. The Whipple instructions called that the PCV filter line and had me connect it from the valve cover to the air inlet tube. My Spectre CAI didn't have a hose connected to it so maybe that explains it. The instructions are for a 2003 since they don't make a kit for a 2002 since they were mostly DBC instead of DBW like mine is so some parts are different. On another note, Justin just got back to me and said code P0200 is my problem, one or more of my fuel injectors isn't connected. I'll have a look tomorrow, it's getting late and I'm beat. Some of those are really hard to get to now.

View attachment 80775

I'll snap a pic tomorrow and post it, mines an 04 I don't recall a hose but I could have missed it


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93blkongreenpro

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Get than injector connected and let's get a vid! Weeeeeeeeeeeeeeeeee!!

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Rocket Man

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So it looks like there's definitely a hose going from the passenger valve cover to the TB correct?
 

95escahoe

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So it looks like there's definitely a hose going from the passenger valve cover to the TB correct?

Well on my 04 it's coming off the intake doesn't really attach to the TB it's exactly like that pic posted above but yours might be different since it's an 02?


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HiHoeSilver

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Like @95escahoe said, ours are newer, and don't come off the TB, but are just behind it off the intake. Here's another pic I found that I think is older than yours, but you can see a hose off the TB:
3809-271653af3232f6c00360e8a6cfde3d92.jpg


It looks to go to the same place. Yes, a nipple on the pass side valve cover.
 
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Rocket Man

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I can take pics of my 13 right now but it wont help you, unless you want them....
No that won't help. Justin thinks it went to the valve cover too, he says it's the same as connecting it to the intake tube. It doesn't seem to matter which way I connect them right now. Weird how they have me connecting the intake tube to the valve cover but I think those 2 locations (intake tube and where it's connecting to the TB) are like Justin said- the same thing. It draws air into the PCV system through the intake air, either at the intake tube or at the TB intake side.
 

HiHoeSilver

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No that won't help. Justin thinks it went to the valve cover too, he says it's the same as connecting it to the intake tube. It doesn't seem to matter which way I connect them right now. Weird how they have me connecting the intake tube to the valve cover but I think those 2 locations (intake tube and where it's connecting to the TB) are like Justin said- the same thing. It draws air into the PCV system through the intake air, either at the intake tube or at the TB intake side.

That's what I was thinking, too. The vacinity of that port is the same, it's just behind the butterfly whether it's on the actual TB housing or the intake.
 
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Rocket Man

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That's what I was thinking, too. The vacinity of that port is the same, it's just behind the butterfly whether it's on the actual TB housing or the intake.
Yep. I left it connected to the intake tube since that's where the hose was routed and then plugged the fitting on the TB with a rubber cap. It didn't make any difference. But I did go out and started replacing the wiring adapters that I got off E-Bay and swapping them with the ones I got from Whipple. I had 2 sets and chose which ones to use. I've replaced 6 so far and #8 had a bent pin and was failed for sure. I'm checking the OEM wiring too, I read they have breaks in the wires sometimes. I started it up and it's better but not there yet. I also might be having a problem with the #8 plug wire. That's the one in the back passenger side that's so hard to get to. I got the plugs replaced but that wire didn't want to go on, can't get a good hold on it to push it on. Maybe there's a way to check with a multimeter to see if it's connected?
 
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Rocket Man

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Thanks. I'm not sure what to do next. I replaced all the injector adapters and reinstalled the plug wires. Already took care of that hose on the TB. It runs the same. When I start it, the rpm's shoot up to about 3000 and then it dies. If I give it gas it will run but real rough. I've reached out to Justin @ BlackBear again to see if he has any suggestions.
 

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Thanks. I'm not sure what to do next. I replaced all the injector adapters and reinstalled the plug wires. Already took care of that hose on the TB. It runs the same. When I start it, the rpm's shoot up to about 3000 and then it dies. If I give it gas it will run but real rough. I've reached out to Justin @ BlackBear again to see if he has any suggestions.

Did you do anything to try and see if that manifold is leaking?
 
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Rocket Man

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Did you do anything to try and see if that manifold is leaking?
I have but it's running so bad it's hard to tell but I think it is. I sprayed TB cleaner around the intake manifold a few times and it seems to really have an effect on the passenger rear side and some effect on the driver rear side. I'm waiting to hear back from BBP. I want to rule out anything else before I undertake that. Not looking forward to removing the blower. Not at all. If it was running a little better it would be easier to check for leaks.
 

93blkongreenpro

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Dam. Just put a thick bead of RTV around it.

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