Hey Guys....
Here is the Back story on my issue.... I have been fighting an exhaust leak for 80k or so....I replace manifold with a 3 piece unit, and still would have manifold to Head leaks inside of 6-7k miles.....I do average of 12-14k a month.... In Florida this last trip, I had the Exhaust gaskets replaced with a One piece unit designed to fill gaps for warpage....No More leak there, but turbo flange cracked, Sooty Filter, = Poor milage, and Black clouds out the back under any load....Driving hard fast and Pulling 6-7 thousand foot passes in Colorado I was down in Second or stopped to cool Off.....Got home And took her in to the Doctor to get fixed....Here is what we did....I cooked the Head....

So

My 1999 4x4 Auto with 318k on it just got a New Used head, valves worked over,Decked the Head to Block as well as Head to Exhaust..newer J/Y turbo that looks good/feels good,had 120k on it... We installed new 275 injectors, adjusted valves going in, First drive on it, My Subaru will out run it.....Boost is only running to about 17-20psi even under max throttle....

We pulled the 275 injectors,re-installed the ??? injectors it had in it when I bought it 130k ago, and it will move out now, but it still will only boost to about 22-25 psi...? I hooked my 28 ft trailer to it ato see if it would pull ok....and I am afraid to get in traffic with it..It is like a NA motor...very slugish, and lethargic.....It had way better power broken than it down now with all the new ish rebuilt parts on it...???? Any ideas...? I am pulling my hair out..... I am ready to blow it up......
Thanks, John

 

Maybe you need a wastegate mod on the replacement turbo to allow.more.air?

 

Did you check for Innercooler boot leaks?

 

you need a boost elbow on a stock turbo to prevent the waste gate from opening early.

also check for boost leaks in the v-clamp to the turbo elbow, and leaks in all intercooler boots.

 

I have been thinking that my stock turbo was worn out because I could not hear the turbo sing so I checked my Innercooler boots and they were hard and cracked, I replaced them and my turbo began to sing "Sweet home Alabama". I still have to check for more leaks and install a Boost Guage.

 

The root problem for my original issue with the turbo was Lack of Fuel due to the MAP SENSOR having broken and exposed wires due to prior owner tying in with scotch locks for a Piggy back Chip....then removing everything and not fixing the wiring....I got to find and fix that problem while on the Road Towing thru Oklahoma.....

Thanks Guys for the input....