So intake gasket was missing ~2" at the back edge. However, no change in boost performance. Im going to try the pressurizing the intake again today, so see if I find some other huge leak.

But get those thinking caps out for another idea! Valves, low compression?

 

waste gate stuck open???

 

Exactly what Im about to check, have visegrips on the hose now!

 

Gonna be a cracked exhaust manifold. Cracked on the bottom side where you can't see it.

 

Checked from the underside, flashlight and creeper, can see the whole thing! Even went so far as to poke around with the dental mirror in other nooks and cannies! There is cracking, but only very, very thin ones. I actually checked for leaks. sprayed with soapy water, start truck, look for bubbles before it gets warm. The cracks arent even leaking the whole length, just little spots.

Now on checking voltage and ohms on MAP and IAT... Ive got 3 wires on the MAP? Im guessing there's a wire easier to stab (similar to APPS adjustment) Anyone know which ones they are and where? Im having a bear of a time trying the get a probe into the IAT, and the MAP, well, I guess I could stab all three... But none of these are easy to get to back there!

 

The wire you probe to check the APPS is on the firewall. The other 3 sensors have to come out to check them. Your just checking resitance on them and not actual current runnin through them.

Those cracks on the manifold will open up under pressure.

I'm on my way out right now but if your still havin issues when I get back I'll hunt down the instructions for these.

 

Duh, forgot about just taking out the sensor, plug it in and check.

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Hmm, since the manifold is junk anyway.... Maybe Ill give it some love ala MIG, and see if I see any improvements.

 

Here's the full article for the APPS. https://www.dieselbombers.com/24-val...tomy-apps.html

IAT Sensor. https://www.dieselbombers.com/24-val...at-sensor.html

MAP Sensor. https://www.dieselbombers.com/5-9l-2...-pressure.html

 

Turbo actuator condemned.

hits 22psi (didnt try to take it farther) nice and smooth and quick. On my local test hill, EGT's also dropped.

Now to stick the banjo in, and chase the hard start issue!

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Nuts, I was hoping... Looks like a waste gate actuator is needed. Interesting though, is the Edge guy mentioned some people just plugging the waste gate hose off, but Im worried, high RPM, long hills would create too much boost. Am I nuts, or should I just plug the line off?

 

BD sells a nice aftermarket wastegate.