OK here's the quick brake down parts done/installed
1.Rebuild engine with Riffraff engine overhaul kit with .030 pistons and all the goodies that come with it.
2. 66mm turbo with 1.0 exhaust housing
3. Converted my fuel system, plenums, spider, and bellow up pipes to the late 99+ setup.
Problems are when towing and are as follow:
High EGT, engine temp according to the idiot light is at 3/4 and I'm sure I'm running hot due to those egts, turbo don't spool until 2K feels like there's a dead spot on throttle from 1/4-3/4 this happens only when towing and on any setting on the Tony Woodman tunes and also on stock setting, I can easily hit 1400 on the heavy tow tune and huber around 1260° on the stock tune and goes up unless I press the OD button off. I can't maintain speed on the highway due to the EGT's I can barely maintain 65 on the highway and still struggling with high egts.

Things done so far as trouble shoot
1. Unplug the chip same thing.
2. Visual check for pre turbo exhaust leaks and there's none,
3. Waste gate is set to around 32 psi but don't have the vacuum line plugged to it plugged it has a Banks Big Head.
4. Boost leaks not sure got to make a tester I'm out of town so I'll try and gather Supply soon. Clamps and boots are good made sure they were good I RE installed the engine.
5. Replaced the dark blue CPS with a spare grey same thing
6. Replaced the MAP sensor with a spare I had same thing
Why did I replaced this sensors you ask?because I haven't RE flashed my pcm to be compatible with my AE it sure would be great right know to monitor ICP and IPR PID's but stupid me haven't done it yet.
How is it possible that my old turbo kept egts under control? but I'm sure I should have my chip return for this turbo correct?

So what can I do right know that I'm on the road that I can test with a multimeter or such. Help would be great.

Oh and there's like 60% humidity and around 90° here in Abilene TX.
Here's what I'm towing



It only weighs in at 8400lbs at the scale house loaded with empty tanks

 

My first inclination is the exh housing. What housing DID you have b4?

 

My old turbo was the Stock TP38, this turbo was design for the SD it's a 4" inlet housing with the 66mm compressor housing and the 1.00 exhaust housing.

 

I have always found Tony's tunes to be great in power and very poor in controlling EGT's. I have three of his tunes on my hydra but never use them. This might not be it at all, just saying.

 

Since I can't compare both turbos given the fact that this engine was rebuild and my old 820K worn out engine was running way lower egts. I could never get above 1180° on my heavy tow setting going up grades, same tunes fresh engine and different turbo, I was expecting low egts but I still need to trouble shoot for boost leaks as soon as I get home I'll trouble shoot and hopefully send my spare PCM to get re-flashed anybody recommend where resend it of too?

 

This is what had to do I couldn't find any coolant bottles so I put an 00 E-250 coolant bottle works great just have fab some brackets.

 

The old turbo had a 1.15ar tho most likely unless I'm just off base here?

 

I think Aaron is right on here. Stock charger of any size with stage 1 sticks is going to suffer while towing, and you decreased the size of the exhaust housing on the turbo, effectively choking the engine. I think the turbo is too small for the injectors you're running. You've almost doubled the fuel going into the engine, no increase on the air going into it, and restricted the air leaving it. Seems like a likely source of the issue to me, but I'm just thinking out loud.

 

You guys think it can be fixed if I sent my chip to get RE-burn? I mean I know I still got to check for boost leaks but this high of egg is a concern I don't want to grenade it just after a fresh rebuild. This turbo was a gift from a friend don't want to say who but I believe with my mods this thing should be golden when towing

 

Adam, I think a chip re-burn might help a lot. Even a stock tune will deliver too much fuel with your stage I injectors. I think what you need is a "stock" custom tune that will limit your stage I injector fuel flow to somewhere near the same as stock injectors. If that can be done.

If I knew much about this topic I'd be making money at it instead of offering questionable free advice.

 

Adam

I have the same problems with the d66. With the stock turbo the egt manageable. I installed the d66 housing on my turbine and have fought egt a lot. My only thought is the 66mm compressor has brought my drive pressure up when trying to spool and my egt has gone up. I am NOT an expert on turbos or their systems this is my WAG at the situation.

About to take it all out and do one of those fancy hairdryers the big boys are using. Lots of money though and need to save up.

 

Is the temp sensor in the same place as the old engine?

 

Yes same spot on driver side manifold.

 

I did my mods in stages.
With stage 1 injectors, wildman tunes, stock turbo, and even intercooled, I had bad problems with high EGTs while towing. Going to the T4 mount and s366 turbo really cooled it down. I giess the s366 moving such a higher volume of air is what does the trick for me

 

The SD units use a waste gate to control the turbo. I have a suspicion the ar of the turbo is tight and dependant on the WG. Now I forget,is that turbo have a ported inlet or just a standard type? Don't forget about the issues SD had in that regard.
I really hate to hear that you are having issues . Having that new mill should be making you happy,not being frustrated.

I have a SD turbo that had a ported housing and was some sort of aftermarket unit. I checked the housing on the exh side but it doesn't say what ar it is. I was hoping it would be looser and I'd send it to you.