I did replace the dash instrument panel four weeks prior to engine replacement. There are some glitches in the lights on the dash such as 4wh and 4 wL indicator lights don't come on and trailer fault light comes on every time I start and have to reset to make it go away. The mileage computer is not matching the fuel gauge ( shows 50 miles to E at over a qtr tank)
So maybe it's just a bad dash. Ford did send the wrong one the first time. ( no turbo gauge) so.....

 

Leo if there is no other signs of egr flow or sensor issues swapping a turbo with a known good one would be the next suggestion.

 

Just a shot in the dark here, but have we Inspected the Air filter box making sure the Bottom of the Box is in Place and the IAT2 sensor is clean ?

 

We are still really flying blind here - knowing what code(s) are in the system would be immensely helpful to the people trying to advise. From the description of "too much airflow" which translates in my mind to "EGR Flow Excessive" we can guess that we are chasing a P0402 which may or may not be accompanied by other EGR or relevant sensor codes.


I was thinking something similar as the engine was just assembled and installed in the truck, something might simply be loose or leaking. A disruption of the airflow across the MAF sensor can cause erroneous readings - we have seen this happen with the use of non-OEM air filters for example and yes, unsecured filter covers. I would also inspect the EBP sensor and tube for leaks as this sensor along with the MAF sensor is critical for VGT and EGR operation.

I would not just toss a turbo at this engine without testing the EGR system and the turbo in that order. The OEM diagnostic equipment has excellent tests that perform static and dynamic tests that will validate the relevant sensors and the operation of the EGR valve and the turbocharger that should point to a successful diagnosis and repair. I do not know what non-OEM tools are capable of or what the OP's mechanic is using... He already threw an EGR valve at it, the turbocharger is much more expensive. Both can, and should be tested before being condemned.

 

What kind of air intake and filter do you have on this new engine? Seems we are assuming it is OEM, but please confirm.