P0299 Disaster

[Karter]

I'm starting a new thread, hoping to get some help from anyone who may have had this P0299 Low Boost code before. I was posting it under the thread Edge Evo issues, but I've taken the Edge out of the picture and the problem still persists. Cerberusiam has been a huge help so far, but we're still not there. This is my daily driver and you can't imagine the level of frustration I'm having with it.

2006 2500 Quad Cab 4x4 Auto. Stock except the wastegate has been turnbuckled closed.

I'm getting a P0299 Low boost code pretty much everytime I drive it, accompanied by Limp Mode. It is totally gutless and sluggish and barely driveable when I clear the code. Obviously undriveable in Limp Mode. I have a boost gauge and can make 25psi of boost, but it makes almost nothing until over 2k rpm. Driving down the freeway is less than 5psi. There doesn't appear to be any leaks, but I'm a newbie, so I'm not completely sure what I'm looking for. I have a vise grip pinching the rubber hose going to the WG actuator. I replaced the MAP sensor, but no change.

The whole code first materialized when I freed up a previously rusted shut wastegate. That was my first mistake. Now that I'm thinking about it, a friend that was helping me with the job heated up the actuator rod with a torch and coated it with copper Never Seize, thinking it would make it move more freely. Would heating the rod damage the actuator internally? But wouldn't crimping the actuator hose prevent air from leaking there anyway? I don't even know anymore.

Any and all suggestions are welcome!

 

[Bob4x4]

first inspect for any restriction in the intake system,pressurize the system and see if the boost sensor reading matches the regulated air pressure.If you have a good scanner compare the sensor readings from the sensor in the air box to the boost sensor.If all is good drop the down pipe and check the wastegate flap
Your truck should be able to hit the low 30's

 

[NIsaacs]

Would heating the rod damage the actuator internally?

Any and all suggestions are welcome!

I would say yes, there is a good chance the spring was damaged and now there is no spring pressure to keep the waste gate shut. Can you move the actuator rod by hand?

PS: On your other thread you said you turnbuckled the waste gate shut. Are you sure you didn't go the wrong way and now it is held open?

Nick

 

[cerberusiam]

Karter, post those scan tool results you captured when the code came up. That will give a good snap shot view of what was happening.

 

[Karter]

Thanks All. These are numbers Cerberusiam was referring to:

Run Time: 310 sec
Fuel pressure: 19936.8 psi
Fuel level: 100%
BARO (InHg): 28.6
ECU Volts: 14.75
Calc Load: 35.3%
ECT (F): 194.0
MAP (InHg): 39.3
Eng RPM: 2091
Veh Speed: 74mph
IAT (F): 91.4

The latest is that the Edge CTS has arrived and been installed, but it has not cured the problem. I genuinely believe the problem really is low boost, and not just a faulty reading. I pressurized the system from the turbo on, and it is leaking down a bit from somewhere, but I couldn't find a leak in any boot or hose or the intercooler. I know the wastegate is pretty janky, since it was all rusted up and wouldn't work freely, hence the reason I turnbuckled it closed. I double checked and I did do it closed. I didn't pull the turbo out and check the wastegate flap, since all the clamps and bolts are rusted to hell and will surely be destroyed upon removal. I am getting between 0 and 3 lbs of boost cruising on the highway at 60mph. I actually think this is getting worse since I got my boost gauge last week. I can't get it past 22psi right now, even under WOT. Up until the last month, I could easily get 30psi.

Although the truck has more power with the Edge tune in it, its still obviously not where it should be and it pours black smoke under anything but light throttle, so there is plenty of fuel, right? That makes me think its in the turbo/wastegate/actuator.

At this point, I'm just going to go ahead and put a turbo in it and get that part fixed correctly. I know its messed up and needs fixing, so I'm just going to do it and get it over with. Do you guys agree?

Thanks.

 

[HDR]

I had this same problem but happened very randomly. It once went a year without coming on! I eventually bought EFI live and deleted the code.

 

[Missouri Mule]

Yes black smoke means to much fuel not enough Air (oxygen).

 

[CKESSEL]

My P0299 issue was from bad injectors. Took me a long time to get it nailed down through multiple tests.

 

[HDR]

My P0299 issue was from bad injectors. Took me a long time to get it nailed down through multiple tests.

What test lead you to injectors? thanks

 

[Karter]

In my case, I think the code is just an indicator of the real problem, which is low boost. When you can't get over 20psi under WOT, with or without a programmer, something has to be wrong with the turbo system. I'm going to replace the turbo as well as all the intake hoses/clamps, as long as I'm there.

 

[WalterJ]

Karter: Not knowing the exact mechanism of potential plugging, how might you chk the Intercooler and intake elbow assy. for good air flow? I worked garage for a while & after some crazy speculation re: new car overheating when on the highway, actually found a 1/2 shop rag in the man's radiator hose!

Good luck.

 

[CKESSEL]

I checked for boost leaks, rail pressure, replaced boost and air intake temp sensors, contribution and some others I can't remember. It started running rough on initial start ups occasionally then became constant which finally showed up as bad injectors. When it would set the code, which happened a lot, it would get a stumble/hesitation under light load.

 

[CKelley1]

I MADE A COUPLER THAT FITS ON THE Intake of the turbo that i can charge with air, i set the pressure at about 15 psi and can check the entire intake in a few seconds, if nothing shows up remove the turbo and remove the exhaust housing, check the wastegate and the turbine blades, i think the gate is open or pieces of piston top knocked the fins off of the turbine, the edge is good about that.

 

[Karter]

I just wanted to give a quick update on what actually was the cause of my low boost problem, and the solution. As it turns out, even thought the wastegate arm was turnbuckled closed, the shaft and flap of the wastegate itself were seized in an open position. I swapped out the whole turbo for a new one and it is making more boost than I know what to do with.

Thanks again to everyone who offered advice, it was much appreciated.

Tim

 

[DonFitzwater]

Glad you solved it. Sometimes stuff just isn't easy!