Edge Evo HT problems on '06

[Karter]

2006 QC 4x4 truck. 200k, Pretty much stock.

I've had this truck for a couple years and I'm pretty sure the turbo wastegate was stuck/rusted shut since I got it. I was told that this wouldn't be a problem with a stock setup, since you couldn't make enough boost to cause an issue, unless you added some fuel, but I did have a simple boost fooler, just to keep it from throwing a code when I was towing heavier. I recently decided to add a Edge Evo HT tuner, so I thought that I should probably fix the wastegate issue to prevent damage, so I freed it all up and got it working again, and removed the boost fooler (so I'd know if it gets stuck again).

Now I have a new problem. The Evo was great for the first couple days, but then it threw a P0299 code, "low boost", after a hour long freeway drive. So I clear the code and carry on, but it just keeps throwing the code and going to limp mode. I put the boost fooler back on, but no difference. So I removed the Evo entirely (boost fooler still on) and reset back to stock. The Evo still says that its locked to my vehicle, and the truck runs like crap, pouring black smoke under medium acceleration. I know I should have a boost gauge, but I don't yet, so I can't say what the boost really is. Is it possible that the wastegate is now stuck open, causing the excess smoke and loss of power? It doesn't look like it is, from the outside. I'm not sure if this is an Evo problem or a boost fooler problem, or a turbo problem. Obviously I'm going to call Edge on monday, but any advice in the meantime?

 

[p-Bar]

Without a boost gauge it's tough to troubleshoot

 

[Karter]

Ordered boost gauge over the weekend.

 

[bigceltic]

Ordered boost gauge over the weekend.

Just fyi, you can also get an Ultragauge and plug it into the OBDII port and it will give you boost as well. I found that it tracks pretty well with my aftermarket/add on mechanical boost gauge.

 

[Karter]

I've ordered a boost gauge from Genos that I should have by tomorrow, but in the meantime, I re-installed the Evo tune, which clearly didn't uninstall properly the last time, and it seems to be working okay for now. I have a 40 mile trip today, so we'll see how that goes. I did get a message from Edge indicating that they would be check into the issue on their end. Thanks again.

 

[Karter]

Update...

The problem never was the Evo HT Tuner, I think it was always the truck. The wastegate was rusty and sticking open. I turnbuckled the gate shut and installed a boost gauge. The weather is crappy here now, so getting any real speed is a challenge, but I was able to make 24psi of boost a couple times with no Low Boost error codes. That was in stock trim. I'm uploading a tune right now, but I suspect it will be fine. BTW...any suggestions on what is a safe max boost pressure on an otherwise stock 5.9L (2006)?

 

[cerberusiam]

35-37 psi is what you want to target.

 

[Karter]

Boy, this problem just doesn't want to go away. So I turnbuckled the wastegate shut, and everything was good for 100 miles or so. Then I shut the truck off for 15 min and I get the CEL again with a Low Boost code. I'm starting to lose hope. Am I going to need to carry a code reader with me as long as I own this truck?!?

 

[Motorhead]

I am assuming you have the stock turbo. You might pull the sensor on the compressor side of the turbo and make sure it is clean. Clean the boost sensor that is mounted in the intake plenum on the head. I fought that code with an after market turbo.

 

[cerberusiam]

There is no sensor on the compressor of an HE351.

Put a boost fooler on it and drive happy, if you are lucky that will clear the confusion on what is high and low boost for the ECU.

 

[Motorhead]

What then is the piece that screws into the compressor side?

 

[cerberusiam]

WG controller.

 

[Karter]

I have a boost fooler on it that is about 18mos old (put on because the wg used to be rusted shut). Maybe the thing has fried out or gone bad? I took it off last night and I'll drive it for awhile and see if the problem continues. Thanks for all the advice so far.

Is the HE351 the turbo that I have (stock)? The wastegate part and the actuator are so rusty. If I ever want it to work right again, I'm probably going to have to replace them, but I'm not sure what model I'm looking for.
********************************************
UPDATE: I did some research and it appears that the HE351 CW is the turbo in my vehicle. A stock replacement seems reasonably priced.

 

[cerberusiam]

Yes, the BF can cause that code also.

The turbo model is an HE351C on your truck.

 

[Karter]

And the saga continues. I have removed the BD diesel boost fooler. I have tried it with the Edge Evo tuner on and off. I have turnbuckled the wastegate shut. After all of this, I'm still getting the P0299 Low Boost code and Limp mode. It usually happens shortly after startup (within a couple blocks). Aside from limp mode, there appears to be plenty of power. Driving on the freeway at 70-75mph is making about 4-5 lbs of boost. Heavy acceleration can easily make 25+psi. Is there a leak somewhere?

This is my first diesel and its been pretty overwhelming dealing with the constant problems on this truck. Its ruined me from every buying another Dodge, for sure. Just very frustrating. Maybe going over to the Duramax forum and reading about their problems will make me feel better...

 

[p-Bar]

I only make about 32 full boost. I am stock along with a smarty but no boost footer. Curious when in limp does your AC work?

 

[Karter]

Its only about 30 deg F here, so I haven't tried the A/C, although I noticed the other day that the A/C compressor is leaking coolant. That's a year old Mopar part, so it's probably time for a replacement anyway.

 

[cerberusiam]

Next step would be change the MAP sensor and make sure the connection is clean and tight.

 

[Karter]

Roger that. I've ordered a MAP sensor. I've noticed that the truck just seems very sluggish since I removed the Edge tune. If I push it at WOT, I can get almost 25psi of boost, but it takes quite awhile to get there.

 

[Karter]

Latest update....

Replaced the MAP sensor. Same problem. After longer (20min +) runs on the highway, the Low Boost code and limp mode will come up the next time I start the truck. The truck still seems weak as well, with little power until 50mph or so, then it takes off.