Good to hear let us know how it goes.

 

This is only meant in jest, now that your long ordeal seems to have ended...but, with boots leaking this badly..."So I tightened those to the point I thought the clamps would strip and gained 7-10 psi at wot.".. and no CCV mod, the problem would've been very obvious from the get go!

 

I wish my long ordeal has ended, but alas, it has not. Also, I did the CCV mod about 1.5 years ago, so there is no oil to be found anywhere in the intake tract. And now that I am at an actual computer, I can type out more details. I had also found a pinhole leak in my boost tube, so the rise in boost is likley in part only a more accurate reading. The trip home today was a deffinitive Holy Crap the truck has no power, still. . I am seeing up to 27psi of boost, but there is just no torque at all. As a for instance, on the gravel roads I was on, the truck would not spin the tires when taking off from a stop. Not towing anything. I could go on and on about stuff I tried this last week, but so far nothing obvious has come to light, other than the PCM. I can make the truck smoke like George Burns, but it will not build boost at low rpms. And the EGT's climb as fast as my speed. When towing I have to leave it in stock mode to keep EGT's in check.

After talking with Jonothon at Swamps, he did nothing to mess with the Map readings, but yet with the chip plugged in my MAP is way off. And at the higher elevations the PCM would not throw the SES light even with 27psi of boost. At near sea level it does. And to add that I have been low on power and boost for some time, but since I don't really race, it was not enough to be a major issue.

So here is my thought. For some reason my computer is pulling all the timing out, really retarding the injectors creating low CP, and therefore lower than normal power and exhaust flow. The lower exhaust flow of course has a negative impact on boost. Even though the truck is still getting fueled, the low boost is causing higher than normal EGT's. With the stock Turbo it was still able to flow enough air to keep up somewhat witht the flow of the stock injectors. Add more injector and bigger turbo with no more exhaust volume (caused by the retarded timing) and the problem is now compounded. Does this sound plausible? Or am I pulling this out of my left ear?

 

Retarded timing is the last thing I would suspect. That is all software controlled.
Lotta smoke = not enough air for the fuel.
Look in Cookie88's gallery for a picture of a useful tool that you can hold over the intake of the turbo and apply compressed air to. It will pressurize the intake system and make any leak very noticable.
Don't discount a large exhaust leak disabling any sort of turbo spool up, either.

 

Dan- Thanks for the followup. I know the timing seems really far out there, but is all I can come up with. I made a special 120 mile trip while camping to get the parts just so I could pressurize the intake. And that was when I found the pin hole leak in the boost gage line and some light leakage from the orange boots on the intake spider. And at the advice of Swamps, One cold morning I started up the truck, had one person hold a board over the tailpipe, one person rev the engine, and I carefully felt around all the exhaust parts before they got hot trying to find a leak of some sorts. Nothing. Also, it is all new parts, and I even Dyno-matted my firewall so it is a nice clean shiny surface with no signs of soot anywhere. And just for the heck of it, I drilled and tapped a pressure port on the intake coming off the turbo so I could read boost levels before and after the intercooler. I saw a maximum 2 psi differance. 27 when read from the cold side, 29 from the hot side.

I am curious can anyone tell me what sensor data does the PCM use to control timing? Or any other ideas?? Next up is trying to put the stock turbo back on.

 

CPS is a big one, Did you do any work on the lower end with your rebuild? (add shim F6TZ-12J027-M to create approximately 0.5 mm (0.020 inch) clearance to timing disk.)

Another is MAT.

 

Ok, if it's smoking and everything is tight, I'm going to call it a fried turbo exhaust wheel.

 

Are your EGT's climbing now with the new chip, or is this still the other one that was conservative?

I'm going to play around on AE with my truck today and see if I can get you some baseline numbers on stock injectors/stock HPOP. Might be worth a shot. I'll post again this afternoon when I get back with results.

 

My EGT's climb with the conservative tune. When towing if I don't leave it stock, the first slight hill I come to EGT's are out of hand.

Some Baseline Readings from a stock truck would be awesome. Including the exhaust backpressure. Thanks Pocket.

Dan- The turbo is brand new, but I am still considering putting the stocker back on there for lack of any other ideas. Hopefully I can make it over to Daryl's (FordForgotten on TDS) today to get a fresh look at it. At this point my mind is so numb I could probably overlook a missing boost pipe alltogether

 

FN,

I'm back with some spreadsheets to email you. PM me with your email address so I can send them to you.

I couldn't get the exhaust backpressure readings. Last year I capped off the tube and sensor to read strictly atmospheric pressure, and so that I wouldn't have to worry about cleaning soot out of the tube anymore. Well I tried to reconnect it today and clean out the tube, but I couldn't get the soot out. It's way too clogged now, I can't get anything through there, it's like hitting a brick wall about 6 inches down. I'll have to figure out how to get in there and clean it. Also I'm running a Garrett BB turbo. Really would have been nice to compare exhaust backpressures with my truck vs yours. If I'm able to get that tube cleaned out soon, I'll run some more baselines with the exhaust backpressure and get that to you.

Just to let you know.... you can laugh at my HPOP pressures. They are pretty pathetic. Stupid weak stock HPOP. And FWIW, my wastegate control DC does the same thing as yours. Stays at 99% no matter what. I thought that was supposed to set a code, but I guess it's normal after all.

 

Pocket- You are too cool. You can email that to me at admin@vegistroke.com. Can't wait to get this thing running right. And on another issue, I did my first breakin oil change today and now it is surging slightly at cruising speeds.

 

Alright, First I have to Say Swamps Diesel is awesome. They sent me a loaner PCM and IDM and new Chip, No Charge. However, with all that, I still have not found the answer. There was one area of light though.

So far, with all settings on both chips, my MAP reads 2psi below Baro, except one. And on all settings, throttle response and spool up are hideous. We are talking 14 second 0-65. Then one program he threw on there just for the heck of it was his al out top notch 530 hybrid with big oil program. Said if the truck doesn't respond to that, then something is really wrong. Well it did respond. and How. First, the map reading was normal, matched that of the Baro sensor. Throttle response is instant, and took 5 seconds off the 0-60. Finally, something. Still seems weak at higher speeds(60+) but there was a very big differance. Interesting thing is he does not mess with the Map at all. So there is something going on electrical. Now taking all ideas.

 

Well Boost is created by exhaust pressure that is created by the explosion that is caused by the compression of fuel and air. So:

1a. Exhaust leaks? (cracked manifold or uppipe)
1b. Boost leaks? (pressurize the Compressor side of the turbo)
2. Hows the compression on that new motor? (valves seating properly)
3a. What is your fuel pressure at idle and WOT (should have >20psi at idle, 30-70 at WOT under load)
3b. What is ICP and IPR duty cycle at idle and WOT
4. Is the intake clear from the filter all the way to the plenums on the head.

 

Alright, finally think I have this nailed down. Looks like it is a tuning issue. Finally decided to pull the chip and install my Edge Evolution again on the 80 hp setting. And low and behold that knocked yet another second off my 0-60 times from the most powerful chip setting. AND,( a very big "and") my EGT's were the lowest of anything else. It spiked to 1100 once. rest of the time at WOT EGT was about 1000. AND my backpressure was the lowest. So Deffinately a tuning issue. Problem is with the edge, it can't control the HPO very well and consequently does not idle for crap, and even dies. But It also tows well.

So finally making some headway. Anyone know of a good local tuner in the NW? I really think I need to get it on a Chassis dyno to tune it. And even with all the recent progress, I would say the truck only now runs as good as it did stock with the ege all the way up.