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Does the turbo exercise on start up? Can you get at the plunger and do the magnet trick, moving the vanes back and forth? IIRC it's a 6 or 7mm bolt to get the plug out, then stick magnet in the bore, should move easily.
No tears in the CAC boots? They need to be cleaned with brake clean inside, as well as the turbo and intercooler surfaces, and clamped down just right.
And no the turbo doesn't exercise on start up. The only thing I've ever heard it do is whistle on start up and it's tone never changes. I've wondered that and it never does vane sweeps. I've watched it on Torque and it never changes. If I turn the high idle mod on I'll hear the turbo start exercising. But other than that nothing. CAC boots are all in good shape and I cleaned them before reinstall.
Double check wiring harness to ensure good contact. They get brittle and can break when removing and reattaching.
Also, did you get the down pipe on properly. I needed a ratchet clamp to move it an 1/16" to align.
How do i do a turbo relearn? And I didn't rebuild it. And yes i cleaned out that tube. Btw, that tube is a PITA when your reassembling.
The MAP tube and hose are on the passenger side of the engine, the MAP is actually on the heater box and the hose runs over to the intake. A small wire will clean it out and a new vacuum hose is easily sourced at a parts store, it is very simple to get to.
How do i do a turbo relearn? And I didn't rebuild it. And yes i cleaned out that tube. Btw, that tube is a PITA when your reassembling.
Not sure what you've actually done? You said you didn't rebuild it.
Did you clean or replace the unison ring to ensure its not stuck?
If you did that and reassembled and aligned properly, I'd expect the 299 to not return for at last 25k.
Was it stuck if indeed you pulled it apart?
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