robp823 Posted August 22, 2008 Share Posted August 22, 2008 OK... im still green so bare with me, make a long story short i just put an engine in an 03 f250 for base engine problems.I got a brand new short block one head and used the other good head off the old engine. I just finished it today idled fine, reved right up, but when i went to take it for a ride everytime i would get on it it would sputter and make a crazy noise coming from the intake i think its called turbo surge. So i brought it back to the dealer popped the hood scratched my head and was going to hook up ids but it was closing time and the tool room was already locked. So i said fuck it lets give it one more shot took a couple practice laps around the parking lot and it seemed better. This is where it gets bad, I decided to take it for another ride and as soon as i pulled out into the main street i just hammered on it thought maybe the vanes were coked up and sticking got to like 4 grand and BOOM! I sware to god this old lady shit her pants that was walking down the sidewalk, pretty funny but anyway pulled over and it blew the right side rubber cac apart and the clamp is just gone have no idea where the hell that thing went. any ideas? This is the first one i ever had blow off on me so any input would be helpful... thanks Quote Link to comment Share on other sites More sharing options...
kevin phillips Posted August 24, 2008 Share Posted August 24, 2008 Cac hoses on the 6.0 blow off quite often.Make sure and clean the hoses with brake cleaner and dry before install.Check also to make sure the truck is not overboosting due to sticking vanes in the turbo.New clamps and the updated hose with the orange inner layer inside might also help. Quote Link to comment Share on other sites More sharing options...
DamageINC Posted August 24, 2008 Share Posted August 24, 2008 Like Kevin said, I'd be checking to make sure that the turbo's not taking a dump. If you're getting heavy compressor surge from simple WOT blasts then that's usually a sign that the vanes aren't doing what they're told. The fact that the CAC hoses don't wanna stay on is also indicative of a sticky turbo. Obviously you need to replace the one that's torn, but clean the other ones off with brake cleaner and a rag before you install them again. And take that turbo apart! Dave Quote Link to comment Share on other sites More sharing options...
robp823 Posted August 26, 2008 Author Share Posted August 26, 2008 Took the turbo apart today i thought it was way beyond servicing but my manager said do the best ya can so i got it back together and back on the truck and its still doing the same thing. P132b overboost and popping through the intake with puffs of black smoke everytime it does. VGTDC is around 85 at idle and only goes down to about 60 when you get on it but i can command it to 0 using output state control?????? also i was looking at the MAF it looks like a rough signal. Are they supposed to look like that???I called hotline and they said check the O-ring that is used on the tube from the intake to the left side valve cover to make sure i dont have air getting in past MAF causing this overboost he said if im still having the same problem get a new turbo any thoughts or advise would be very apreciated Thanks!!! Quote Link to comment Share on other sites More sharing options...
Keith Browning Posted August 27, 2008 Share Posted August 27, 2008 Actually that is not a bad thought. I would take it a step further and REMOVE the entire intake tube at the turbo inlet. Check the green o-ring as mentioned but pay attention to the tube where the crankcase breather goes into the large tube. The rubber tends to deteriorate from contact with oil and cause leaks. Quote Link to comment Share on other sites More sharing options...
kevin phillips Posted August 27, 2008 Share Posted August 27, 2008 Have you done a relearn procedure for the egr?cleared codes,koeo on-demand and looked at the vgt learned pid which should say yes after a hot idle time of a few mins. Seems like i had one that i forgot to relearn that was puffing black smoke and had crazy boost problems on hard accel.If the truck has the latest calibration it might be worth a shot. The ids turbo test may also help to verify maf to see if it's in range and a egr ids test and visual inspection might show a problem there. I had a egr valve that would open without any effort a few months ago that acted up similiar to your problem. Let us know what you find. /forums/images/%%GRAEMLIN_URL%%/borgsmile-1.gif GOOD LUCK Quote Link to comment Share on other sites More sharing options...
Mekanik Posted August 29, 2008 Share Posted August 29, 2008 Are you sure you tightened all of your intake and CAC clamps? I don't mean to insult you, but I have seen it before. If you have any air or exaust leaks, you will have problems with an early build and the later calibration. Did you look to see if the unison ring in the turbo cracked? Perform the re-learn procedure as previously mentioned. FWIW, I always tighten those CAC clamps to 108 in/lbs. Its tighter than it sounds. Quote Link to comment Share on other sites More sharing options...
robp823 Posted September 4, 2008 Author Share Posted September 4, 2008 how do you do vgt relearn? Quote Link to comment Share on other sites More sharing options...
Keith Browning Posted September 5, 2008 Share Posted September 5, 2008 how do you do vgt relearn? Rob, we forget sometimes that we have members that are not only new to the DTS but new to Ford diesels. Click on the attached file on the Inferred EBP Functional Overview which explains how the EBP sensor was eliminated on 2003 production engines. The EBP sensor was the source of a lot of driveability problems. Most trucks with 2003 production engines should have an engine calibration that "strategically eliminates" this sensor and a turbocharger adaptive learning must be performed... read! Please. /forums/images/%%GRAEMLIN_URL%%/smile.gif I have also included the Inferred EBP PID List and description document. Quote Link to comment Share on other sites More sharing options...
robp823 Posted September 5, 2008 Author Share Posted September 5, 2008 thanks very much Quote Link to comment Share on other sites More sharing options...
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