Overheating/codes help

[moneypit6.0]

Hi guys,
I finally had a chance to pull my trailer from OC to Vegas over the weekend. After spending $15k on my head gasket (look for "priceless head gasket thread") I figured the truck will "run like a champ"(mechanic shop's quote). Truck struggled to go past 50mph, coolant temp 220-230 oil climbed to 240 on the hills and around 220-224 on flat. My EGT's are close to 1300 degrees. My boost never went over 8lb and if it did the temp spiked and EGT's alarm was going off.
On my looney tune I get alot of black smoke (I don't use this for towing) my tow tune I get a little black smoke (I think this is normal) I was told also that I might have a hole in the intercooler. I'm thinking about getting banks techni cooler, monster exhaust although I’m not sure if this will fix the problem.
Question
1. Can faulty FICM be a cause for low boost levels or its the intercooler? (running 48volts at idle)
2. Will i get a significant drop in EGT's by going with exhaust/IC combo?
3. Is it the tunes? Tuner?(SCT X3)
4. could it be the strategies on the truck?
5. how likely is it the hole in the intercooler ?
Hoses were checked and some replaced so I doubt those are the problem.
Brand new radiator installed, ballbearing turbo, 8 new OEM injectors, b proof oil cooler and EGR cooler.

What would you recommend with my heating and power issues?
This picture was taken while towing about 16,000lb up the hill right after city of Baker on the way to vegas

Also here are the codes I get

P0407 EGR sensor B Circuit low
P0488 Throttle Position control range / Performance
P1000 On-Board diagnostics OBD system readyness test not complete
U0306 Software incompatability with FICM

these stay even after I clear them or idle the truck for about 30 min to see if it re learns

[Term3]

Try disconnecting the batteries for a few minutes, take the positive cable and ground it then put the batteries back in and reconnect them. If your codes come back, take your tune off and put it back to stock tune to see what happens.

[moneypit6.0]

I did all that and still have the same issues. I'm currently in stock tune

[Lilpooh]

Did you check the up-pipe/y-pipe exhaust flex joints for cracks. With only 8psi of boost and high EGT, it sounds like you have either a exhaust leak between the exhaust manifolds and turbo, or you may have a leak on the CAC side of the motor.


Did you have a good look at the IC boots/pipes/inner cooler! Just doing a visual inspection of the boots may not be enough, sometimes the boots rip under the clamps where you can't see it unless you remove the boots to inspect, especially the 45* boot coming off the turbo.

You can also check the hose and fitting for the MAP sensor, it may be damaged or blocked with soot. Also may be the EBP sensor or metal tubing blocked up with soot.

[moneypit6.0]

I dropped it off at the dealer,
I was told there is a hole on the intercooler, which will cause my EGR codes etc. I have Banks intercooler and monster exhaust (turbo back) on order from XDP but its on back order till may 7th.

Quick question:
My AC stops working at times when I tow or if my coolant is at 220+ is that normal? maybe a safety mechanism?

Originally Posted by Lilpooh

Did you check the up-pipe/y-pipe exhaust flex joints for cracks. With only 8psi of boost and high EGT, it sounds like you have either a exhaust leak between the exhaust manifolds and turbo, or you may have a leak on the CAC side of the motor.


Did you have a good look at the IC boots/pipes/inner cooler! Just doing a visual inspection of the boots may not be enough, sometimes the boots rip under the clamps where you can't see it unless you remove the boots to inspect, especially the 45* boot coming off the turbo.

You can also check the hose and fitting for the MAP sensor, it may be damaged or blocked with soot. Also may be the EBP sensor or metal tubing blocked up with soot.