I have an '01 (see sig line) that starts and runs fine. It's bone stock as far as performance mods. I did all the baseline maintenance on it after buying it last year - fuel and air filter. Turbo play is normal, turbo is not dusted. Gets 14-15mpg highway and high 13s in town. Opacity during emission tests is 1% (kinda low).

I bought it with a bogus (wrong year) Hypertech power programmer, and last year, showed 191 hp at 60mph on the dyno during the emission test. Most 7.3s around here show 205-215. I later had the shop return it to the stock Ford program and ditch the Hypertext tool.

This year, the dyno test showed 172 HP at 60mph (which is 1900-odd RPM with my 3.73 gears). It did show 191 hp in the 2nd gear test, so there is more boost at higher RPMs.

I'm starting with the assumption that I have a boost leak.

The diesel shop next door suggested installing a boost gauge as a first step. Here are my questions:

1) He said I should see 12-15 psi as a max boost while driving (read at the MAP gauge - or presumably the AIH housing). Is this correct?

2) I have done a boost leak check, but was unconvinced. I presume that removing the hard aluminum intercooler tubes would allow a full inspection of the lines and boots? This is a pain, but it's hard to see the lines among all the junk in the compartment. Can you really find the leaks with soapy water in the hidden areas?

3) I've heard of disabling the wastegate as a diagnostic step to check boost. Can anyone tell me how? - or if this is even a good idea?

4) I recently cleaned the EBPV line and sensor, which were plugged, but I understand that this typically affects mileage, not power, right?

5) Can a boost leak cause low opacity, or is low opacity driver of low boost? My opacity indicates low fueling.

Where else should I look for my power loss? I'm feeling the need for a full set of gauges, here, too.


Thanks,

Steve (Colo Springs, CO)