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It not being able to self check ain’t good ! It will not set it self in the right spot to run right! The way I understood this set up is ! Is it gauges it’s self at every start up comupter then decides where to run it if don’t stroke right it gauges wrong so it doesn’t run where it’s spose to! just sayin!

Yup

Sounds like there’s No boost gauge working blind here!

Has anyone looked at the codes on this yet! There is a wheel speed sensor on the turbo the green wire it may be faulty!

Have her turn the key on don’t start let it do it’s self check! Yup Soot is not good! Worn actuator shaft!

So you have air to the turbo? you said you cracked that line?sorry don’t want to keep beating a dead dog here you need to confirm it’s stroking correctly! Also when you start the engine in the morning no air in the system you should hear a change in the sound when your air pressure gets around 70 psi it will start to sound like Kirby vacuum cleaner at that point if it doesn’t then the egr valve is stuck open or the turbo is not working right! That could be the contoler or the turbo itself! With out checking we can’t help! I we are not there we are here we can only tell you what to look for!

This whole time?

Probably and it maybe stuck open! If it’s stuck open it won’t let the turbo spool up!

Dodger do you know where the egr valve is? Unplug it and see if the truck drives better!

Where does that plastic line go? It normally goes down to the filter if it hasn’t been deleted?

Behind the oil filter s

Motor

Should be directly below the controller!

Copilot I believe! Is there no screen in it? Is there no boost gauge to your left in the gauge cluster there? If that had a screen you would have had an option to look at boost oil pressure and some other vitals . Mpg ect!

Ok So Get the engine warmed up to temp! If you have a Boost gauge! Watch the boost! Rev the engine to max rpm! And feather it back and forth drop back 300- 500 rpm and back up to max top rpm do this half a dozen times see what kind of boost it generates! It should make around 15-20 psi just sitting there doing this! if so If its working as it should! It should sound like a kirby vacuam cleaner While you do this!🤣

Did you check the Turbo VGT for stroke KEY ON?

Follow the plastic line that leads to that controler back down the VGT filter should be directly below it near the oil pan! also There should be a valve on the fire wall to shut it off to change that filter!

The ai stock was a dog but reliable! With the proper mods manifolds and or an ac cam they perform well! All this stuff let them breath properly!they worked well ! Aside from the odd bad turbo they worked well with mods!Hope we can get you worked thru your issues!

You first need to check the operation of the vgt ! as stated if it strokes correctly once you confirm that and plug the egr if the egr valve is commanded open by the puter it won't matter no egr gona flow and it will not loose any ability to spool the turbo! essentially becomes a normal engine !I did this to a customers truck 2005 chn years ago the truck lived a long life aside from a the check engine light being on all the time the truck did over 1 million miles! no problems to speak of !

Same Idea Joe ! Different Concept is all! The statement wasn't Meant to degrade your opinion! These can carbon up too! BorgWarner turbos! These were a disaster at first these were popping left right and center in the first year till they got a handle on the programing! The trucks would come in with 10 lbs boost at idle! a wheel speed of 43000 rpm! Once they dropped the wheel speed down to 23000 and boost to more or less zero ! the issues seem to go down to a dull roar! My theory was the side loading with lower oil pressure they never told us what the issue really was! other than heat!😡 Typical! Need to know basis stuff! your not included! We had half a dozen trucks on the sales lot robbed of turbos just to keep guys running for the first six months! Embarrassing as hell!

yup have seen this done never done it ! however no support! Essentially if you put a plate beneath the EGR valve and the manifold flow is stopped no need to arouse suspicion! mums the word! removing the cooler means you got coolant line and stuff to plug just extra work!

This turbo has no nozzle It has variable vanes! Check to make sure it is stroking! Yes it can still be electrical! You still may have to free up the shaft and pin! Make sure it hits the stops top and bottom!

The vane control could be!they sometimes seaze! try turning the key on and check if the vGT strokes it should go full stroke then back to start position! Does a self check every time the key is turned on!

I have capped off the egr flow on these they run fine but will throw a code for low egr flow!They usually don’t derate! what kind of boost do you see? You should be seeing at least 33 psi! 35 plus is normal under load!

Yup they reduced this as Joey said ! As long as the fuel pressure doesn't drop off when the rpms are increased under load you should not be having power issues related TO FUEL PREASSURE !