Turbo underboost condition after turbo replacement

LaMont Owner/Technician Smithville, Ohio Posted   Latest   Edited  
Question
Driveability
2012 Ford F-250 Super Duty Lariat 6.7L (T) 6-spd (6R140)—1FT7W2BT7CEB05089
P0299 - Turbocharger/Supercharger "A" Underboost Condition

We replaced the turbo on this truck. Also replaced the air filter and cleaned the charge air cooler. After driving it a couple of days we now have a P0299 (turbo underboost condition). The engine runs fine and it seems to have plenty of boost. I checked the charge air cooler hose and it appeared to be installed correctly. I can actuate the wastegate solenoid with the scan tool and it appears to be operating correctly. EGR position voltage is .89 KOEO. Egr pressure sensor 1 KOEO is 14.1 psi. Does this pid seem to be correct? We don't do a lot of diesel work. We are just getting our feet wet. Also, we don't have a high volume smoke machine to check for leaks. Can anyone provide some direction on this? Any help is greatly appreciated.

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Mark Owner/Technician
Kent, Washington
Mark Default
 

Not really a Ford tech but I've done a lot of Mercedes diesel repairs. Trust the computer, you left something loose. It's under boosting. The computers are real smart and although you may think it's ok, it's not you that matters. It's the computer. So if you do not have a high pressure smoke tester, I suggest you borrow one. Remember...... I'm not a Ford tech so you may want to see what a…

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Rex Technical Support Specialist
Alliance, Ohio
Rex Default
 

I am not a big fan of the smoke machines on heavy duty diesels. Not enough pressure IMHO. We have cuff seals on the Navistar MaxxForce DT's that don't leak until there is 15 to 20 or more psi against them. We use our Charge Air Cooler (CAC) test set up. Connect at the turbo output and manifold inlet. Put 25 to 30 psi in thru a regulator. You will likely hear it. If not soapy water in a spray…

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Marlin Technician
Estacada, Oregon
Marlin Default
 

Really? 43 psi isn't enough? aeswave​.​com/smart-pressure…

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Rex Technical Support Specialist
Alliance, Ohio
Rex Default
   

Marlin, this is the first I have seen this. We were force fed a Red Line machine as an essential tool about 5 years ago. For more than twice the money. I was very unimpressed. This at first glance looks to be much better. Lack of pressure was the problem with the Red Line. At least I have a nice set of adapters! The air pressure set up has worked OK for us on medium and heavy duty. I have also…

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JB Owner/Technician
Minneapolis, Minnesota
JB Default
 

Lisle makes a block off kit that allows you to pressurize the cac piping so you can find leaks. If you do any turbo vehicle repairs, get one.

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Mike Owner/Technician
West Palm Beach, Florida
Mike Default
 

I just ordered the light duty kit for that. I had the HD one already, but most of the adapters are too big. I got taken by the local Matco guy on that. He insisted the HD kit was the one I needed. Once I tried to sue it and found out it wasn't, he refused to take it back. Useless tools is starting to become a theme with Matco. It's leaving a bad taste in my mouth.

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Paul Owner/Technician
Mondovi, Wisconsin
Paul Default
 

You've stated you replaced the air filter. This TSB might give you a clue about what's going on with this Ford: 16-0004. Try this TSB while you're at it: 19-2143. The factory service manual, step KA2, has a whole bunch of inspection points to look over on these before hitting them with the smoke tester. After the initial steps, then, like the others posted...bring on the smoke.

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Andrew Technician
Odessa, Texas
Andrew Default
   

You need to pull the map sensor on the top on the intake and make sure it's not plugged. Send a picture of it and I can tell you. All I work on is powerstroke. I would start there first

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LaMont Owner/Technician
Smithville, Ohio
LaMont Default
 

I found a leak at the CAC pipe fitting at the throttle body. Had to replace the whole pipe. Ran the KOER test and now I have a P1249. when we did the turbo we also replaced the upper intake with a Dorman. It had a new MAP sensor in it. I’m seriously wondering if it’s not working correctly. Is there a way to check it other than substituting a known good?

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Marlin Technician
Estacada, Oregon
Marlin Default
 

Why did you replace the manifold? Dorman means that is most likely is not working correctly. Why not just test it with a vacuum pump and gauge? The PID and the gauge need to match within a couple in/Hg.

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LaMont Owner/Technician
Smithville, Ohio
LaMont Default
 

Manifold was replaced due to having to break it to remove bolts. I don't agree with the blanket statement about Dorman although some of their stuff is problematic.

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Marlin Technician
Estacada, Oregon
Marlin Default
 

Interesting. Were the bolts seized due to rust, and the hex not enough to loosen them? Did you test the sensor?

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LaMont Owner/Technician
Smithville, Ohio
LaMont Default
 

Yes, the bolts were seized due to rust (Ohio road salt). The rust had actually split the plastic where they went through. Testing the sensor as you suggested was a good idea, however, I tried substituting a different sensor(see my revision above). thanks for your involvement.

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Scott Manager
Claremont, California
Scott Default
 

Can you share the FF data and or any data you collected when the vehicle enters this mode? Your question about the EGR pid is probably normal and reporting atmospheric pressure. There are a ton of resources like this and more at the Motorcraft website.

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LaMont Owner/Technician
Smithville, Ohio
LaMont Default
 

Scott, Thanks for the information. I couldn't find any information in Alldata, Pro Demand or Identifix as to what it took to run and pass the turbo monitor. Also could not find any sensor values. What you sent was enlightening. I didn't save the freeze frame data before I cleared the P0299 code so I don't have that to show. I wish I would have since I haven't been able to get the code to…

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JB Owner/Technician
Minneapolis, Minnesota
JB Default
   

Remember if you're roughly at sea level 1 atmosphere is about 14.5psi. So any sensors that measure air pressure should read around this if they are absolute pressure sensors with koeo (gauge pressure sensors read zero at 1 atmosphere). So this applies to the MAP sensor as well as the exhaust backpressure sensor.

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LaMont Owner/Technician
Smithville, Ohio
LaMont Update
 

I ended up using my gas engine smoke machine and found a lot of smoke coming out where the CAC pipe fastens to the throttle body. The o-ring on the inside had worn flat where it contacted the throttle body. There was not a replacement to be found in the U.S. so I replaced the complete pipe assy. I road tested it and the P0299 code did not return but the monitor has not completed to this point…

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Marlin Technician
Estacada, Oregon
Marlin Default
 

This still points to unexpected MAP signal. Did you check over the small vacuum hoses? Did you ensure that the MAP sensor hole isn't faulty?

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LaMont Owner/Technician
Smithville, Ohio
LaMont Default
   

Yes, I removed the map sensor and inspected it. The hole in the intake is open. If it wasn’t working I would think I would have other codes. I have a actuated the wastegate solenoid with a scan tool and a vacuum gauge teed in and I get 15 inches of vacuum at 100% duty cycle. Thanks for working with me on this.

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Marlin Technician
Estacada, Oregon
Marlin Default
 

I think that one has a vacuum operated valve at the EGR cooler also. Did you go over all of the vacuum hoses?

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LaMont Owner/Technician
Smithville, Ohio
LaMont Default
 

I didn’t check vacuum there.

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Caleb Diagnostician
Mishawaka, Indiana
Caleb Default
   

Hey Lamont. Just my opinion. I would say that the p0299 caused the PCM to never run the monitor for the P1249. The P1249 has probably been there for awhile but didnt set till you fixed p0299. The MAP is used for determining the actual boost pressure. If there was a problem with the MAP it would not pass P0299. In fact the MAP was doing its job because it set P0299 and you found a leak to prove…

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Helpful
LaMont Owner/Technician
Smithville, Ohio
LaMont Default
   

The wastegate moves when I command it with the scan tool. When I checked it I had a vacuum gauge teed in and I had 15 inches of vacuum @ 100% duty cycle. I have not watched it while the KOER test is running. This was a new Garrett turbo. I assume they are properly adjusted when you get them. There was a paint mark on the adjust rod so we didn’t move it before installing it. If the truck comes…

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LaMont Owner/Technician
Smithville, Ohio
LaMont Resolution
   

Hi everyone, Finally got this one fixed today. It came back after a week with the same P0299 code. In my last update I had stated that I had 15 inches of vacuum. I guess I'm too used to working on gas vehicles because that would be enough vacuum to operate anything vacuum related on a gas car in my experience. I decided to test the vacuum harness and I found out that it would leak down. The…

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Caleb Diagnostician
Mishawaka, Indiana
Caleb Default
 

Awesome good deal.

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LaMont Owner/Technician
Smithville, Ohio
LaMont Default
 

Thanks for your help.

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Rex Technical Support Specialist
Alliance, Ohio
Rex Default
 

Good find. I am surprised they use vacuum. The diesel I work with use the boost from the turbo itself to run the wastegate pod. They use pressure, not vacuum.

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