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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.