Low boost Code/ Gen. Maintenance/ Compressor Surge and everything else

[Donny Johnston McClure]

My inlaws wanted a Truck Camper combo that gets decent gas milage . I have no diesel experience but have rebuilt gas rigs plus the usual maintenance in my own garage/shop.

Found a 2004 Ram 2500... 144,000 miles Little if any tea kettle with oil cap loose on oil. Recommended check from friend
Since two months ago... day one of purchase weird noise on hard acceleration .. seems to work through it ( go away as you continue to accelerate.. possible slight very slight delay, I am used to gas volvo x/c70 Turbo response) Also seems to happen when accelerating them take your foot off the pedal... I am just reading up on compressor surge and other terms.. Had a code 299 low turbo boost and speed sensor code, engine light and limp mode on a 300 mile trip. I reset with OBD ll ran fine for 800 miles but I was staying away from hard acceleration. Codes came back and would not reset.... History and learning curve so far appreciate your time !!


1.
K and N carb sticker under hood CARB 269-26 .
I believe it is for the filter and elbow to compressor of turbo?
The K and N looks like it needed cleaned.... inlaws bought a replacement non K and N filter from orielliys before I told them I found a stock one in a wrecking yard for 75.00 hope its still there.. re potential reason for compressor surge?

What I have done maintenance/ parts shot... wise so far ...
Replaced the open exhaust with stock 4 inch/ mufflers.Old system rusted out and blowing exhaust on rear diff.... Local Friend 250.00 sounds much quieter.

Replaced All Ball joints/U joints on drive axles/stab and drag links tie rod ends with Moog greasable parts from Rockauto... 500.00 Drives within the lines now.

Changed engine oil after seafoam ran in crankcase for 100 miles...

2.looking at quality fuel filter? your forums recommendations will also clean the IAT Sensor Fuel milage seems all over the place via stock computer reading plus turbo flutter/ compressor surge..

3. would like to check MAP sensor as well? Tips?

4. Just noticed fan belt shredding engine edge

5.Codes came back after 200 mile trip.Wont reset. Low boost speed sensor plus low fan speed code. I started checking for leaks / loose exhaust fittings via forum recommendations .... The turbo to Exhaust nuts not on very tight at all... looks like ebay compressor just installed... no name on it and silver with adjustable waste gate looks like original waste gate solenoid reused......
thought I was getting some excessive leaking noise while idling but I did not put a hand around to feel for leaks, sorry just jumped in and pulled turbo

bought gasket kit... left manifold on ... really felt like they did not tighten to torque specs it came off so easy, one stud in back came off with nut/seized on.. it was the loosest one.

Cleaned all gasket surfaces, cleaned out carbon , spins well no marks seen,disconnected waste gate to manually check gate itself works but when putting actuator back on was tight SHOULD IT SLIDE BACK ON WITHOUT TENSION?? Adjust?? Thanks!
put back on added oil directly to turbo before top line bolted on.
I did disconnect batteries while working on it. Codes Gone .
Drives better ... less compressor surge but still there under hard acceleration ?????? Ill recheck nuts and all connectors. Planning on stock air filter replacement and learning about waste gate adjustments and sensors....

Also replaced belt and tensioner with Gates brand..... after checking pulley play and pulley alignment belt seems not to be moving or shredding.

6.Started getting a bit of oil out the ? Blow by tube ? underneath... read something about canister? will check manual....

7. Appreciate any maintenance tips

 

[Donny Johnston McClure]

So did a test drive after turbo re- installed, new gaskets and torqued down exhaust/turbo 4 15 mm nuts ( they were loose) compressor surge down by 75 percent on hard acceleration. This morning noticed slight oil leak from oil return line under turbo retorked to specs... was 5 lbs under approx.... also replaced fuel filter , cleaned MAP sensor next to fuel rail and IAT/MAF sensor next to K and N filters.... retested pretty much all compressor surge gone unless you really put the petal to floor and then only slight surge and maybe a bit of flutter... YAH!!

So as I was learning about this situation one piece of advice that kept coming up from others was to test for leaks... have some one do it our build a pressure tester your self..... then you'll know where the leak is.... I am sure new fuel filter and cleaning sensors helped as well !

 

[Donny Johnston McClure]

Via onboard computer getting 19 to 21 mpg flat road about 63 mph... still need to check/learn about crank case vent tube blowing out a bit of oil

 

[Donny Johnston McClure]

Found the person before had not reinstalled turbo to torq specs plus waste gate actuator was holding waste gate slightly open also replaced MAP sensor.... no codes for now !

 

[Donny Johnston McClure]

Codes came back, replaced MAP sensor, codes cleared by themselves without my OBD II.
Now need to figure out how to set preload on wastegate .... testing to see when it opens by what PSI.... I want to set it up for MPG. It looks like a aftermarket compressor and wastegate replacement ... no name on it.