Electronic wastegate issues (2006)

[BHolm]

I am still trying to figure out what is going on with my turbo/wastegate. I added a Quadzilla box to the truck and while it solved the problem I used to have, something still isn't right.



The wastegate will not maintain boost all of the time. Sometimes it will spike at 36-38 and hold pretty well. Other times it wont climb above 26 and the box is still fuelling making smoke and pushing EGTs up. Other times it will hit 36 and as the rpms come up it will bleed down once again resulting in high EGTs.



I am assuming that boost fooling feature should be telling the wastegate to remain closed. So if it is still not building the boost it should, and dropping boost other times, where should I start to figure this out?



Can the electronic wastegate be replaced with a mechanical version? Is it possible I have a bad actuator? What would be a good way to check it? I noticed the rod actuating the gate is adjustable, should I mess with that?



I sure could use some advice on this bugger. I really do not want to take it to the dealer, you know how some dealers are. It was an issue that existed before the box was installed. The box actually fixed the symptom I was having stock, but clearly the problem still exists.

 

[Bob4x4]

assuming you are running the stock turbo,pull the hose off the electronic solenoid (leaving it in place) and run an old style boost fitting from the location of your choice to the actuator. You will now have consistant #s.



Bob

 

[jwilliams3]

TST has a manual wastegate kit. Its included with their TST CR powermax.



Boost fooler is just that a boost fooler. It doesnt operate your wastegate.

 

[Kday]

Got a manual wastegate controller from TST for my 05 with a Juice/Att, only problem I had was too high of boost-44 psi. I now have it down to 35 psi, just didn't want to blow up my stocker. You might have a weak wastegate head.

 

[BHolm]

assuming you are running the stock turbo,pull the hose off the electronic solenoid (leaving it in place) and run an old style boost fitting from the location of your choice to the actuator. You will now have consistant #s.



Bob

So it just needs manifold pressure to work? How about a T in the line to the boost gauge? Is the fix that easy?Oo.

 

[Bob4x4]

It is that easy as long as your actuator is not blown out.



Bob

 

[BHolm]

So does that mean that pressure is applied to the actuator, not vacuum, to make it open the wastegate?



If the actuator is bad, is it availible seperately?



I have a vacuum pump that I could test the diaphragm with but it sounds like what I need to do is apply pressure instead.

 

[CDonaldson]

I would bet that the service manual tells you how to test the actuator's function. Might be some simple thing to do. Since I am only familiar with boost/boost relief on gassers and have not taken the time to understand the peculiarities of our systems, this is all good info to know.



Thanks guys. CD

 

[Bob4x4]

So does that mean that pressure is applied to the actuator, not vacuum, to make it open the wastegate?



If the actuator is bad, is it availible seperately?



I have a vacuum pump that I could test the diaphragm with but it sounds like what I need to do is apply pressure instead.

That's right the actuator sees boost pressure,when the set pressure is reached the actuator will begin to open. To test apply a regulated air pressure to check calibration and to insure no leaks in system.



Bob

 

[BHolm]

Today I ran a 1/4" line from a boost bolt directly to the wastegate actuator. I removed the old hose and plugged it leaving the elec solenoid in place. I took a T off this new line to the boost gauge.



Now it appears that all I get is 25-26 lbs of boost. It is certainly more consistent but not really what I had hoped for.



Is it possible that the actuator is set for 25-26 lbs and the solenoid was actually allowing higher boost by not releasing the pressure to the actuator until boost had built higher?



So my choices are...



1) Actuator spring is weak, replace actuator



2) Actuator is fine, elec solenoid was acting funny, replace it



3) Install some sort of aftermarket part, Banks Big Head, manual boost controller from TST... . other?



Any votes? Cost is a factor!

 

[jwilliams3]

You forgot one thing... .



A restrictive boost bolt. This will delay the wastegate opening.

 

[Bob4x4]

Today I ran a 1/4" line from a boost bolt directly to the wastegate actuator. I removed the old hose and plugged it leaving the elec solenoid in place. I took a T off this new line to the boost gauge.



Now it appears that all I get is 25-26 lbs of boost. It is certainly more consistent but not really what I had hoped for.



Is it possible that the actuator is set for 25-26 lbs and the solenoid was actually allowing higher boost by not releasing the pressure to the actuator until boost had built higher?



So my choices are...



1) Actuator spring is weak, replace actuator



2) Actuator is fine, elec solenoid was acting funny, replace it



3) Install some sort of aftermarket part, Banks Big Head, manual boost controller from TST... . other?



Any votes? Cost is a factor!

The factory set-up will allow up to the mid 30psi range,the electronic solenoid is controlled by the ecm. When under heavy load the solenoid is powered up allowing the boost signal to bypass the w/g actuator through an internal passage.

If you use a boost fitting from any of the many performance companies that has a restrictor and bleed hole you will see higher boost #s under load.



Bob

 

[BHolm]

I put a major restriction in the line and now have better boost numbers. I have to think the thing is almost completely plugged and the turbo will now make 36 lbs when on either of the two higher settings on the Qzilla.



I have to wonder if altitude is playing a part in my lower than expected numbers. I live at 8000ft, yet I always saw pretty close to the same as everybody else stock, right around 30 psi. Am I starting to get out of the efficient range when I get up around 36? The Qzilla tech guy expected more like 38-42 psi from my truck. Personally I think 40 psi is about as hard as I want to push the stock turbo. I also realize that I am now pretty close to what they expect. Is this about it?



With the restriction in the wastegate line I now have much less smoke and EGTs climb much more slowly, as expected, and this is a good thing



Thanks for the help!

 

[231jasonS]

At 8K feet my boost numbers fell off a lot. On my 04 i had a WSB which was just that, a W. icked S. on of a B. $%^h. That thing ran great, but at elevation it fell on its face. I thought my wastegate was stuck open and i pulled the turbo to find nothing wrong. As soon as i got back to 3K feet it was fine again.