I built a boost leak test cap, finally found time to use it. Hooked it up at about 20 psi, the gauge on the test cap doesn't even move. Plenty of fartin' around trying to find a leak I can hear. Finally accidentally found it. It's coming from the crank case. The oil dipstick tube, and the cap if I take it off. My gut us telling me it's something catastrophic, but my sense of denial tells me it's something simple I'm missing. I bumped the engine over a couple times to change which cylinder would be getting the pressure and leaking through the rings with no change. The truck has zero blow by when running so I'm telling myself it can't be rings. It essentially burns no oil. My first oil change went 5000 miles and didn't even use enough oil to need to add any. My second oil change has about 800 miles on it, 500 of which were pulling heavy, and the level is still where it was on fill up. The only smoke I get is on cold startup, it's grey, and only for about 5-10 seconds. I can get some black smoke on a WOT takeoff, but only until the turbo catches up, then it's gone.

I got FORScan set up last night. I don't understand how to use it yet, but I did find the test section. The injector test and cylinder contribution test both passed. I did the KOER On-demand test and came up with a P0476, exhaust back pressure control valve performance malfunction. I also got a C1284, oil pressure switch failure at the instrument cluster. There is a host of other codes, most not related to engine.

I'm really at a loss here. Ready to try anything you guys think of.....

 

Are you attaching the boost tester directly to the hose coming from the turbo? You want to attach there if you can, and eliminate the CCV from the path. You will still hear and feel a breeze from the CCV during this test, but you should be able to build pressure easily - or there is a significant leak somewhere.

 

Would like to see the codes you have if you can post a screen capture of them. Then you can clear them with FORScan and then drive the truck a bit and see what codes are still there - those are the ones to pursue.

A how-to thread for FORScan is below:

https://www.ford-trucks.com/forums/1...d-q-and-a.html

 

Dang! Thank you!!! I am hooked up before the CCV. I’ll go try again.

I’ll try to figure out the screen shot of codes after I do the boost test.

 

That did the trick. I don't feel like I'm about to have catastrophic engine failure.....

Still not building any pressure, but I have leaks on the turbo to intake boots. I have a set of plenum inserts and boots from Riff Raff sitting on the bench for next weekends project. O ring kit and up pipes will all be getting done at the same time. Also all the front end coolant system parts.

Here's the initial code code log.



This is the page from running all the tests. IT's in 2 parts, I have a small screen.

 

Ok, now that you have a record of what codes the truck has been storing, go ahead and clear them. Let's see what comes back after a drive or 2.

Any drivability problems you're having currently? Assuming you have low boost?

There are codes for EBPV and ICP that we'll look at if they come back.

 

I haven't been able to get above 23 lbs of boost. Even pulling a 15K lb 5th wheel. I have that flutter/chirp kind of sound I have been chasing as well. I'm hoping it's the intake boots chirping. It comes in around 15 lbs of boost at different rpm's. I can keep it away by easing back on the throttle. EGT's seem a bit high. If I get all conditions right, I can get the EGT up above 1200 in OD running empty. Up pipes will be here Monday and I'll move the EGT probe out of the pipe to the manifold as well.