working on a friends 03, turbo recently acting up has a 4 in turbo back and at idle the turbo screams like the vanes are stuck and doesnt quite have the low roar tone higher up in the rpm range, tore apart the turbo cleaned and de sooted everything applied high temp anti sieze and reinstalled. in ideal its alittle quiter but still sounds like your on the tarmack next to a f16. builds boost now where as before the vanes would stick open and wouldnt build boost. does the vane controler go out on these things or what?

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one thing i did notice is the base that the vanes sit and ride on was very pitted where im assuming it should be a finished surface so the vanes change smoothly we did our best while de sooting it to polish it up a bit but still pretty pitted.

 

Did you or him have the batteries disconnected for a prolong amount of time? Is yes, you may want to try the VGT relearn for the '03-early '04.


KAM (keep-alive-memory) reset & VGT learn procedure
1. Drive the truck until the engine and transmission have reached normal operating temperature.
(The VGT learn procedure requires that the oil and coolant temperatures be at normal operating temperature)
2. Flash truck back to stock (Only need to do this if running a tuner or module)
3. Turn on the headlights
4. Disconnect both batteries
5. Short out + to - battery cables to each other (Make sure both batteries are disconnected before doing this).
6. Let truck sit like this for 10-minutes
7. Turn off the headlights.
8. Re-connect batteries
9. Cycle the key to the run position twice. Pause in the “ON” position each time until the wait to start lamp goes out (minimum 5-seconds) and pause in the “OFF” position each time for 10-seconds to be sure the PCM has "gone to sleep".
10. Start the truck and let it idle for a minimum of 5-minutes at normal operating temperature. This allows the PCM to learn the EGR valve closed position value. Also you will likely hear the turbo pitch change several times during this period as the PCM learns the necessary duty cycles for accurate VGT control.
11. Complete the road test Drive Cycle:

15 miles of mixed driving (*should* be enough in most cases) to allow the PCM to "re-learn"
its adaptive strategy. Note: Anytime the batteries are disconnected, the PCM will throw the
P1000 code until the “Drive Cycle” is completed. As for the Tow/Haul mode, the transmission
must re-learn your driving style and loads hauled again as this was cleared when the truck was
re-flashed.

 

You probably need to replace that unison ring if it was pitted that bad. These turbo's stick quite a bit, typically on trucks that are driven like grocery getter's or idled for long periods of time.

 

the ring that sits on top of the vanes was in good shape ( the one that controls the vanes open or closed when the **** is turned) it was the base that they ride on that has the projections the vanes sit on. it looked like it was cast into the turbo or pressed on is it replaceable.

 

You don't happen to have a picture of it do you? Can you find it here: DTS Articles - Turbocharger Reconditioning

 

Have you read the manual for the procedures to perform the Drive Cycle test?? It's more than 15 miles. I don't think ANY tech ever actually performs this test when required.

 

plugged the egr valve back in and the problem seemed to go away? not sure how we have unplugged the valve since he has owned the truck and have not had a problem i know that this doesnt solve the egr cooler and associated problems but until he had the money to fix it the right way we opt to unplug it for now