Stock Wastegate Preload instructions for MPG please

[Donny Johnston McClure]

I was getting a lot of compressor surge on our inlaws new/used 04 5.9.
After reading up here, I checked for a leak and found the exhaust to turbo was not mounted to tightly at all and leaking/hissing. It has a new "no name" compressor and wastegate, ( no name I think) . Once I removed cleaned and remounted the turbo compressor surge gone. Cleared low turbo boost code. Truck was running great for 200 miles then codes and limp mode again. Replaced MAP sensor since on inspection gasket looked compromised and housing cracked, codes reset by themselves, no limp mode.
I have a gasser background with some turbo rebuild experience on Volvos , so I understand the basics.

QUESTION:
What should the preload be set at for the wastegate ( some sites say no preload( non dodge) ( Some say 6 turns but I do not want to build boost or blow head gaskets)...So how many turns from when the linkage just fits ( what PSI to test its good) ? It was set at approx 6 turns shorter......I want to set it for max MPG, it is only used to carry a bigfoot camper. Appreciate the help.
Donny

 

[Donny Johnston McClure]

PS I own a vacuum mighty mite tester if that helps

 

[lpennock]

Stock wastegate is set at about 24psi. 04 can run at 30 without problem I'm just not sure when it with throw over boost code if you don't have a boost fooler. 04.5 can run 32 without codes and run 35 easily.

 

[Donny Johnston McClure]

Bought this truck used at 144000 to haul a bigfoot camper for inlaws, hopoing to get at least 15mpg.

Low boost 0299 code , cleaned MAP sensor also noticed exhaust to turbo not on tight at all so took off replaced gasket, cleaned out carbon from waste gate pucks and housing, reinstalled tightened to tork specs .
When I reinstalled I left wastegate with no preload from a post I read on a turbo site ( Non Dodge) This eliminated the compressor surge ( If I am using correct term) but after 30 miles 299 underboost code came back. Replaced MAP sensor engine reset the 299 code itself and came out of limp mode this time.
I also set the preload on the waste gate at 3 turns ( I believe it was at 6 turns originally) this time and used approx 20 PSI to reinstall arm.
Slight compressor surge returned, turbo also seams loud to me ( has always seemed loud )but engine runs strong.

Drove 400 miles with camper 70 mph no issues. Code came back , limp mode as well.. shifted manually to make it up hills code reset itself..... then code came back.... unplugged MAP sensor started engine..... turned off replugged in MAP sensor used my OBDII to reset codes went away on restart ran 400 miles home no codes....... may build a tester to test turbo side for leaks. ?? I would like to identify this turbo. Replace if it will increase MPG and decrease noise.... also want to replace the K and N air filter with stock filter. ..... thoughts ?

 

[AH64ID]

Any gauges on the truck?

Is the low boost code genuine or false?

You want the wategate to open at approx 22-24 psi of compressor pressure. Without knowing the specs on the turbo/wastegate it will be nearly impossible to tell you what the "preload" should be. You need to set it with a pressure gauge of sorts. If you "preload" it too much and it opens prematurely you could cause EGT issues and potentially motor problems, especially since it will be used to haul a camper.

Fuel determines mpgs on a diesel, not airflow... generally speaking. The wastegate should NOT be opening in a cruise profile.

Yes ditch the K&N. See if you can find a stock intake.

What is the hp rating on the valve cover?

 

[Donny Johnston McClure]

Any gauges on the truck?

Stock only 2004

Is the low boost code genuine or false?

I do not know but causes the truck to go into limp mode.... I have rebuilt heads on our gassers and have a decent home shop with air tools.... I was thinking I could set up my mityvac between the wastegate and compressor to test?

You want the wategate to open at approx 22-24 psi of compressor pressure. Without knowing the specs on the turbo/wastegate it will be nearly impossible to tell you what the "preload" should be. You need to set it with a pressure gauge of sorts. If you "preload" it too much and it opens prematurely you could cause EGT issues and potentially motor problems, especially since it will be used to haul a camper.

thank you , that makes perfect sense just rteying to diagnose issue.... was thinking of pressure testing turbo system as well, with 30 PSI....

Fuel determines mpgs on a diesel, not airflow... generally speaking. The wastegate should NOT be opening in a cruise profile.

I do not think it is due to the compressor noise increase when you punch it plus if you do not let off the throttle getting mild compressor surge/flutter sound.... these decreased when I set the preload at half the turns it was at..... waste gate and compressor look newer to me......

Yes ditch the K&N. See if you can find a stock intake.
Found One will install this weekend

What is the hp rating on the valve cover?

??

Valve cover says 24 V cummings thats it unless I am totally missing something 2004 dodge 2500

I really appreciate your comments and all the tips !

 

[AH64ID]

??

Valve cover says 24 V cummings thats it unless I am totally missing something 2004 dodge 2500

I really appreciate your comments and all the tips !

There should be a sticker like this on the drivers side of the valve cover.

 

[AH64ID]

I do not know but causes the truck to go into limp mode.... I have rebuilt heads on our gassers and have a decent home shop with air tools.... I was thinking I could set up my mityvac between the wastegate and compressor to test?

You will need to hook it up to compressed air and not vacuum to test. As you increase air pressure to the WG it should start to move about 22-23 psi.

thank you , that makes perfect sense just trying to diagnose issue.... was thinking of pressure testing turbo system as well, with 30 PSI....

Good idea, then you can rule out any air leaks.

I do not think it is due to the compressor noise increase when you punch it plus if you do not let off the throttle getting mild compressor surge/flutter sound.... these decreased when I set the preload at half the turns it was at..... waste gate and compressor look newer to me......

I would recommend a boost gauge, or if you can get your OBDII reader to act as a gauge.

If you're not wanting to install gauges permanently in the truck an Ultra Gauge is a great little reader/gauge and they are pretty cheap. I see they have a bluetooth gauge now for the same price as the wired gauge.

Found One will install this weekend

Good call!

The OEM 4" pleated filter can't be beat for that box. The Wix filter is the same filter so buy whatever is cheaper.