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Jul 2, 2012 | 02:41 PM

PaulwestSki

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Cross-Country

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No Boost / Sorry Long Post

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9; mso-style-qformat:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin:0in; mso-para-margin-bottom:.0001pt; line-height:115%; mso-pagination:widow-orphan; font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:"Times New Roman"; mso-fareast-theme-font:minor-fareast; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin;} </style> <![endif]--> 2005 Excursion 6.0L
54,000 miles
Engine is stock except coolant filter.
EGT, boost, Trans temp gauges

I last drove the Excursion at the end of April 2012, Mountain and interstate driving towing a light trailer, only weighed about 4k. Truck ran perfect.
Okay I know I should drive it like I stole it once a week….hard to do when you’re out of town for two months at times
Went to drive it about two weeks ago (June 20<sup>th</sup>) and had a check engine light.
I hooked up the AutoEnginuity software and had the following codes:
P0299-Turbo under boost
P0401-Exhaust Gas Recirculation "A" Flow Insufficient Detected
It’s not the first time I’ve had the P0299 so I knew the VGT needed cleaning.
I didn’t clear the codes.
I figured it was time for the EGR delete, and new oil cooler, coolant flush, ELC coolant, maybe head studs, gaskets and new exhaust while I’m that far into it. I was trying to come up with a good method to raise the body off the frame without a lift.

So the power steering pump seized on my F-350 and I needed to drive the excursion to work. So Sunday afternoon I went to clear the codes off of the excursion so I could drive it the next morning and had an additional code……..

P0299-Turbo under boost
P0401-Exhaust Gas Recirculation "A" Flow Insufficient Detected
P-2262-Turbo boost pressure not detected-mechanical

I couldn’t believe the no boost until I looked at my mechanical gauge as I increased RPMs to 3k and the gauge stayed on 0psi……..WTF.
Okay I’m not driving that tomorrow.

I figured to start with the basics and remove the air filter and check the turbo compressor wheel for play and that it spins freely….no issues with the compressor wheel.
I did find a substantial birds nest in the air filter housing (pre-filter) well that makes sense the truck couldn’t breathe, no boost. (I’ll post pictures later) Cleared the codes still no boost. Time to do some research.

Okay checked the MAP sensor, MAP sensor tube, none of them are clogged.
Pulled the EGR valve to clean, it was pretty clean already, cleaned it up installed new o-rings and gasket re-installed.
Pulled the EBP sensor and tube none of them clogged.
Had to pull the air filter housing to gain better access to the EBP tube to exhaust manifold fitting and low and behold the birds had built another nest in the air filter pre- filter (one week later mind you). I then fabricated a ¾” mesh screen to fit over the ZooDad mod hole and cut some hardware cloth to fill in another area to block the birds access to the air filter intake.

Cleared all of the codes and checked the Barometric pressure reading and MAP reading with a dead cold engine. Seemed normal both the same.
Started it up and stall have the P-2262-Turbo boost pressure not detected-mechanical
No boost registering on the gauge either.
Test drive no boost until 45-50 mph in 3<sup>rd</sup> accelerating heavy but not hard 10-12 lbs of boost

What the hell, do I need to pull the exhaust because the squirrels have built a nest in the exhaust.
I do have exhaust flowing out of the tail pipe.

I want to resolve the NO boost issue before I tear into everything to install the EGR delete and other bullet proofing mods.
Sorry for the long post
ANY SUGGESTIONS????????

Jul 2, 2012 | 05:33 PM

cheezit

Post Fiend

Joined: Oct 2009

Posts: 12,123

Likes: 35

From: N. Fort Worth, tx

yup I would seperate the 2 nut off the cat and push the pipe back a little bit to start with. also check the carge air cooler to see it you have an o-ring sticking out of the tank

Jul 2, 2012 | 06:04 PM

m-chan68

Lead Driver

Joined: Mar 2010

Posts: 5,504

Likes: 256

From: Woodbridge, Ontario, CA

How about doing the following with your scan tool, if you can in the following order:

-Take active command of EGR duty cycle to 0%
-Take active command on Engine RPMs and increase to 1200 RPMs
-Access MGP psi
-Take active command of VGT duty cycle, and toggle between 0% to 85%

Monitor your MGP psi data. It should read 0 psi with VGT @ 0% and about 2 to 3 psi peak as you increase VGT duty cyle to 85%.

This test will tell you if your turbo/VGT is actually functioning. Failing that, your next step is to "borrow" a VGT solenoid from another known good 6.0L truck to try. If that fails to correct the condition, try disconnecting the downpipe from the catalyst (two 15mm nuts) and driving it to see if the condition improves. That'll tell you if you have a plugged exhaust. If all of the above fails and you have confirmed you have no intake/exhaust restrictions/leaks, then it's time to pull the turbo to clean or replace.

Jul 8, 2012 | 04:12 PM

PaulwestSki

Thread Starter

Cross-Country

Joined: Jul 2005

Posts: 74

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Update

Unhooked the exhaust from the cat and I could hear the turbo spooling.
I've ordered the turbo re-install and cleaning kit.

Jul 8, 2012 | 11:23 PM

BLADE35

Hotshot

Joined: Apr 2010

Posts: 19,055

Likes: 235

From: Saratoga Springs,UT

Quote:

Originally Posted by PaulwestSki

Unhooked the exhaust from the cat and I could hear the turbo spooling.
I've ordered the turbo re-install and cleaning kit.

So it all got better when the exhaust was removed???

So you have a Plugged Cat????

What did AE say for EBP psi????with exhaust hooked up still???

Jul 9, 2012 | 07:38 AM

zhilton

Logistics Pro

Joined: Mar 2007

Posts: 4,604

Likes: 4

From: Claremore, OK

Quote:

Originally Posted by PaulwestSki

I've ordered the turbo re-install and cleaning kit.

Not sure what all you've ordered, but I think you find that the only thing you need to clean & re-install the turbo is this:

4C4Z-9V424-AA Reconditioning Kit.

It has the high temp anti-seize, 3M discs, gaskets, o-rings and bolts used on the turbo. I used to think you needed 3C3Z-9T514-AG; but when I opened the reconditioning kit I discovered all the parts were there for installation of the turbo.

Jul 31, 2012 | 12:01 PM

PaulwestSki

Thread Starter

Cross-Country

Joined: Jul 2005

Posts: 74

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Update

I tore it down and the unison ring was rusted to the housing. The vanes weren't too bad.
The amount of carbon on the ring and housing was unbelievable. It's a good thing that I ordered a extra box of the 3M coarse disks/pads because I needed them. Anyone planning on cleaning their turbo should definitely have extra disks on hand.
I try not to short trip the truck and have the SEIC mod so excessive idling shouldn't be too much of an issue. If I'm idling its at 1300 RPM
I think the problem is it's not my daily driver and may not get driven for a month or so at a time.
From now on once a week it will get driven and exercised.

While I was under the hood I installed a new oil cooler, EGR delete, STC update, turbo oil supply and drain update, fuel pressure regulator blue spring update, new thermostat, had the intake hot tanked, new MBRP 4"turbo back exhaust, New oil and fuel filters, air filter has less that 1500 miles on it.

Before I started the work I added Fumoto block drain valves and did an extensive cooling system flush with Restore and then VC-9 and then twice with distilled water. I used tap water to flush after the Restore and VC-9 treatments and back flushed the heater cores. I then filled the system with CAT ELC ran it to operating temperature and then drained into clean buckets to re-use. I changed the coolant filter after all of the flushing and it had syrup like gel in it.
All of that flushing and treatments pretty much takes a whole day.

I just have to button up a few things and then I'll be ready to start it.

I'll update then

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Jul 31, 2012 | 12:16 PM

PaulwestSki

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Cross-Country

Joined: Jul 2005

Posts: 74

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Birds Nest

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Jul 31, 2012 | 12:17 PM

#10

PaulwestSki

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Cross-Country

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Picture didn't load

Aug 5, 2012 | 01:54 PM

#11

PaulwestSki

Thread Starter

Cross-Country

Joined: Jul 2005

Posts: 74

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Update

Truck runs great now.
Boost is back.
Topside creeper paid for itself.
I had one leak the metal heater tube to front cover o-ring split.

I just about pulled my hair out looking for the FICM grommets.
The 05s don't use the grommets, they're built on the brackets where they bolt to the valve covers. Although my local dealer sold me some 03 grommets. I may go ahead and install them anyway it can't hurt.

The MBRP has a nice growl at higher rpms but no stupid droan while cruising.
I purchased different exhaust clamps to use for the install. I found the stainless steel band type for slip fit tubing and they worked really well.

I do have the EGR CEL and ordered the SCT iTSX from Clay to turn it off.
Once that's installed I'll take a long drive and check the ECT EOT delta.

Birds nest link
https://www.ford-trucks.com/user_gal...&albumid=43703

Last edited by PaulwestSki; Aug 5, 2012 at 02:22 PM. Reason: add Link

Aug 5, 2012 | 02:37 PM

#12

Fal-308-Win

Posting Guru

Joined: Jun 2012

Posts: 1,452

Likes: 0

From: Nor Cal

I laughed my a$$ off reading your post,
sounds like you need the Ford/Mossburge
12 gauge mod.

Aug 17, 2012 | 04:19 PM

#13

diesel-fitter-bum01

Posting Guru

Joined: May 2009

Posts: 1,468

Likes: 0

From: Battle Creek, NE

So what exactly fixed it? Cleaning the turbo?

Dec 10, 2012 | 10:32 AM

#14

PaulwestSki

Thread Starter

Cross-Country

Joined: Jul 2005

Posts: 74

Likes: 0

Quote:

Originally Posted by diesel-fitter-bum01

So what exactly fixed it? Cleaning the turbo?

Yeah reconditioning the VGT was the trick

Dec 26, 2012 | 09:32 PM

#15

Gary Lewis

FTE Legend

Joined: Jul 2010

Posts: 32,875

Likes: 48

From: Northeast, OK

Could you guys help me? I usually hang out on the 80 - 86 forum and know quite a bit about 351M's. But, I know nothing about diesels save for the theory of how they work. However, a buddy of mine has a 2006 F250 w/a 6.0 and he said he's getting a check engine light and when he pulls the code it says "low boost". But, in reading this thread and a few others I'm wondering if he's getting P0299-Turbo under boost. Is that likely?

And, I know you are going to think of me the same as I did of another guy earlier today when he said he doesn't know the difference between a voltmeter and an ammeter. But, what's a VGT? Is that what needs to be cleaned to solve this problem? Sorry to be so dense, but I'm lost and don't know what to tell him.

Thanks in advance.

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