Low boost and turbo noise after EGR cooler job - Ford Powerstroke Diesel Forum
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post #1 of 8 Old 08-21-2019, 08:21 PM Thread Starter
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Low boost and turbo noise after EGR cooler job

This was my first EGR and oil cooler job on a 2005 F350. I installed all new gaskets and O-rings from the kit and also replaced the turbo with a reman unit. The only thing I didn’t replace were the exhaust clamps, but I did tighten them to the manufacturer spec of 9ftlbs. Upon installing everything and plugging the harness, I noticed the VGT harness was peeling apart showing bare wire and was shorting out. Repaired that part of the harness. When I started the truck and immediately noticed a loud hissing sound from the turbo that would come and go. Disconnected the charge pipe, and pressurized the intake with 40psi, which is the maximum psi the 6.0 makes at high loads. Found a small leak at the EGR valve but very small. I found it odd since it’s a new one, and I torqued it to spec.

So I fired it up again, connected my scan tool, and took it for a test drive. Besides burning off residual coolant in the exhaust for miles, I also noticed low power, and not enough boost pressure, maybe 25 psi at most. No active codes, so I came back to the shop and did a few tests. The engine compression test showed cyl 7 about 10% lower than the rest. So I did the VGT test, and that’s were I found the noise. The higher the VGT duty cycle, the louder the noise, but I find it odd why would it be at 60% at idle. Best way to describe the noice is an exhaust leak, but the clamps are right, and there’s no evidence of exhaust leaking. Am I looking at a faulty VGT solenoid? The turbo kit came with a new one installed so I think it’s highly likely. If anything I’m regretting reusing the clamps. Especially the EGR cooler clamp which seems just about impossible to replace without taking the whole thing apart again.

Any insight would be very appreciated.
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post #2 of 8 Old 09-07-2019, 11:59 PM Thread Starter
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Update: a few weeks and about a thousand miles later, I checked the truck out. And a quick look at the turbo, I see it covered in exhaust soot. A closer look also showed soot all over the EGR cooler and pedestal. The turbine side is relatively clean with little to no soot. First thing I did was remove the VGT actuator, but it seemed normal other than it being coated with soot. Where else would this turbo be leaking from? Am I dealing with a bad reman turbo (I replaced the turbo along with the EGR cooler)? I’m really not looking forward doing this again that’s for sure.
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Last edited by 1neeto; 09-08-2019 at 09:59 AM.
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post #3 of 8 Old 09-08-2019, 04:39 AM
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You can test for exhaust leaks by duct taping a shop vac to the tailpipe and put it on blow. I found three this way both feeling for the leaks and using bubbling leak checker. Ive also used a 3 rubber pipe boot bought from Home Depot with an air chuck installed and pressurized to find leaks. This way, I could also hear the leaks. With this, I found leaks in the exhaust gas manifold, up pipes, Y-Pipes, and EGR clamp.

Exhaust leaks are very hard to find. I had one that only showed up under load. I put a set of aftermarket Y-pipes and up-pipes in. They did not fit well and I knew things would not go well when I first put them in and had to use a crow bar to make it fit. An air check like I mentioned done when the turbo was still off with the Y-Pipe clamped off revealed I had put the EGR clamp in incorrectly and was leaking. Still leaking when I went on a drive. In my case after days of troubleshooting, I gave up and brought it to a shop and they fixed it.

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post #4 of 8 Old 09-08-2019, 10:07 AM Thread Starter
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Quote:
Originally Posted by ChrisSki View Post
You can test for exhaust leaks by duct taping a shop vac to the tailpipe and put it on blow. I found three this way both feeling for the leaks and using bubbling leak checker. I’ve also used a 3” rubber pipe boot bought from Home Depot with an air chuck installed and pressurized to find leaks. This way, I could also hear the leaks. With this, I found leaks in the exhaust gas manifold, up pipes, Y-Pipes, and EGR clamp.

Exhaust leaks are very hard to find. I had one that only showed up under load. I put a set of aftermarket Y-pipes and up-pipes in. They did not fit well and I knew things would not go well when I first put them in and had to use a crow bar to make it fit. An air check like I mentioned done when the turbo was still off with the Y-Pipe clamped off revealed I had put the EGR clamp in incorrectly and was leaking. Still leaking when I went on a drive. In my case after days of troubleshooting, I gave up and brought it to a shop and they fixed it.
The leak is only active when the VGT is at 60% duty cycle or higher. So blowing air through the tail pipe will show nothing, I pretty much ruled out the clamps because the clamp area is relatively clean. Most of the soot is on the center cartridge and compressor side.
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post #5 of 8 Old 09-08-2019, 12:38 PM
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Start the truck, and within 2-3 minutes, the engine should automatically kick up the VGT% to 85% to help the engine warm up. Get a 2-3' section of 1/4" or 1/2" hose and put one end to your ear, and probe around the truck with the other end. If you have a leak, you will definitely hear it!

Or, if you have AutoEnginuity or another S/W program that lets you control the VGT%, kick it up to 85% at idle and then probe around with the hose.

Where did you get your reman turbo from? Have you contacted them to see if they have any ideas?

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post #6 of 8 Old 09-08-2019, 02:51 PM Thread Starter
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Originally Posted by jokester00 View Post
Start the truck, and within 2-3 minutes, the engine should automatically kick up the VGT% to 85% to help the engine warm up. Get a 2-3' section of 1/4" or 1/2" hose and put one end to your ear, and probe around the truck with the other end. If you have a leak, you will definitely hear it!

Or, if you have AutoEnginuity or another S/W program that lets you control the VGT%, kick it up to 85% at idle and then probe around with the hose.

Where did you get your reman turbo from? Have you contacted them to see if they have any ideas?

-jokester
I have a snap-on scanner that allows me to control the VGT duty cycle. Did quite some reading, and I should take a closer look at that exhaust y-pipe. Apparently those tend to leak if they’re not perfectly lined up, and the symptoms are quite identical from what I’m experiencing. Also read something about the flex pipe breaking during turbo installs.

The brand of the reman turbo escapes me right now since I already turned in the core.
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post #7 of 8 Old 09-08-2019, 04:30 PM
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Quote:
Originally Posted by 1neeto View Post
I have a snap-on scanner that allows me to control the VGT duty cycle. Did quite some reading, and I should take a closer look at that exhaust y-pipe. Apparently those tend to leak if they’re not perfectly lined up, and the symptoms are quite identical from what I’m experiencing. Also read something about the flex pipe breaking during turbo installs.

The brand of the reman turbo escapes me right now since I already turned in the core.
Don't rule out the turbo just yet. Any of your exhaust connections could be blowing the soot, however, since you said the EGR cooler clamp is clean, I would definitely check the Y pipe connection and all around the turbo where the turbine housing meets the CHRA. If you can, take the metal heat shield off the top of the turbo when you check. You might just find your culprit when you do that! Whatever is leaking, you will find it with the hose trick for sure!

-jokester

2005 F350 CCLB FX4 Lariat
SCT SF3 - Currently running PHP 80hp Daily Driver Tune with Atlas 40 FICM Tune
Edge Insight CTS2 monitor
Edge EAS EGT probe
Edge EAS Fuel Pressure Sensor
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post #8 of 8 Old 09-08-2019, 06:10 PM Thread Starter
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Quote:
Originally Posted by jokester00 View Post
Quote:
Originally Posted by 1neeto View Post
I have a snap-on scanner that allows me to control the VGT duty cycle. Did quite some reading, and I should take a closer look at that exhaust y-pipe. Apparently those tend to leak if they’re not perfectly lined up, and the symptoms are quite identical from what I’m experiencing. Also read something about the flex pipe breaking during turbo installs.

The brand of the reman turbo escapes me right now since I already turned in the core.
Don't rule out the turbo just yet. Any of your exhaust connections could be blowing the soot, however, since you said the EGR cooler clamp is clean, I would definitely check the Y pipe connection and all around the turbo where the turbine housing meets the CHRA. If you can, take the metal heat shield off the top of the turbo when you check. You might just find your culprit when you do that! Whatever is leaking, you will find it with the hose trick for sure!

-jokester
Yeah I’ll try that hose trick. Also I think it’s a good idea to remove that heat shield. Thanks!
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