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6.5L Diesel Engine Discuss the 6.5 GM diesel engine & associated components. Automatic transmission questions & problems belong in the 4L80/85 - 4L60E - 6L90 Transmission Forum

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Old 10-29-2015, 07:35 PM   #1 (permalink)
saffron98
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No Boost P0236 + More

I am getting no boost from my turbo. Truck has 200K on it. I recently replaced my waste-gate solenoid valve and boost was restored:

20150916_073051_resized.jpg

During a 6 ton haul at highway speeds I was boosting 5 PSI and all of a sudden my boost failed.

I'm getting 25 HG at my vacuum pump:

20150902_200319_resized_1.jpg

I'm getting 16 HG at the waste-gate actuator.

I'm getting voltage at the wate-gate solenoid valve.

When I hook up the vacuum pump line directly to the waste-gate actuator I STILL do not boost.

Vacuum lines have been replaced with silicone hoses (no leaks).

I can operate the wate-gate actuator arm freely when the engine is off. When the engine is on and pressure is applied to the wate-gate actuator arm it goes down, and than immediately up when released.

This all left me scratching my head so I replaced my beat up crossover pipe with one from SS Diesel Supply:

20151010_083504_resized.jpg

Still no boost! Current Codes:
P0236 Boost Sensor A perf
P0251 Injection Pump fuel metering control
P0370 Timing reference high resolution

Engine bay before silicone lines were installed:

20150830_100544_resized_1.jpg

20150830_100603_resized_1.jpg

Ideas?

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1997 GMC 3500 Dump 6.5L 2WD
Badger Diesel rebuilt GM8 Turbo
Glowshift Boost Gauge
Heath Diesel Turbo-Master
4" Turbo Back Diamond Eye Exhaust / 2.25" Cross Over Pipe
SS Diesel HD Lift Pump
Bosch Injectors / Duraterm Glow-plugs
Heath Diesel PMD Isolator System
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Old 10-29-2015, 10:08 PM   #2 (permalink)
JMJNet
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You should not be able to move it at all when engine is running.

There is a possibility that the wastegate actuator is bad or the solenoid is bad.

By the way, don't start throwing part at it.

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1995 GMC Suburban:
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Leroy Diesel Flight System PMD
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Last edited by JMJNet; 10-29-2015 at 10:09 PM.
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Old 10-30-2015, 08:57 AM   #3 (permalink)
saffron98
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Quote:
Originally Posted by JMJNet View Post
You should not be able to move it at all when engine is running.

There is a possibility that the wastegate actuator is bad or the solenoid is bad.

By the way, don't start throwing part at it.

I tested the wategate actuator with the engine off and the hose removed. I placed my thumb over it and was able to move the arm up and down with a screwdriver with minimal force.

Time for a Heath Turbo-Master?
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1997 GMC 3500 Dump 6.5L 2WD
Badger Diesel rebuilt GM8 Turbo
Glowshift Boost Gauge
Heath Diesel Turbo-Master
4" Turbo Back Diamond Eye Exhaust / 2.25" Cross Over Pipe
SS Diesel HD Lift Pump
Bosch Injectors / Duraterm Glow-plugs
Heath Diesel PMD Isolator System
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Old 10-30-2015, 11:12 AM   #4 (permalink)
paleyjim
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My actuator take a LOT of force to move when the engine is running. How hard did you have to push on the arm to move it down? Do you have a hand operated vacuum pump (common for bleeding brakes)? You could try to pull the actuator up with this and verify that it doesn't leak. You could also pull the arm up and then cap the actuator with your finger and verify it doesn't come back down.

A turbo-master may fix your problem. Lots of guys on here like them. I'm currently happy with the factory setup. Lots of different opinions to read through on this site.
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96 ECLB, T4 S300, High Output DS4, +0.010 gaskets, Diamond Cups, ARP head studs, Custom stainless exhaust: 3.5" DP, 2.5" Crossover, 4" DP back.
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Old 10-30-2015, 11:29 AM   #5 (permalink)
JMJNet
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Quote:
Originally Posted by saffron98 View Post
I tested the wategate actuator with the engine off and the hose removed. I placed my thumb over it and was able to move the arm up and down with a screwdriver with minimal force.

Time for a Heath Turbo-Master?
Test it with engine on and hose intact.
You should NOT be able to move the wastegate assuming the VP and everything is good.

Did you measure the vacuum at the VP directly?
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1995 GMC Suburban:
PMD in Bumper
Leroy Diesel Flight System PMD
Leroy Diesel Oil Cooler Line
4" Warpspeed Exhaust
Kennedy Diesel LP/OPS Harness
Bosch Duraterm GP
Heath Turbo-Master
AD244 Alternator

Last edited by JMJNet; 10-30-2015 at 11:29 AM.
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Old 10-30-2015, 08:27 PM   #6 (permalink)
saffron98
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Quote:
Originally Posted by paleyjim View Post
My actuator take a LOT of force to move when the engine is running. How hard did you have to push on the arm to move it down? Do you have a hand operated vacuum pump (common for bleeding brakes)? You could try to pull the actuator up with this and verify that it doesn't leak. You could also pull the arm up and then cap the actuator with your finger and verify it doesn't come back down.

A turbo-master may fix your problem. Lots of guys on here like them. I'm currently happy with the factory setup. Lots of different opinions to read through on this site.
Vacuum pump and waste gate solenoid are fully operational and I do not have any clogs or leaks in my new silicone lines.

When I apply manual vacuum and pressure to the waste gate actuator the rod goes up and down.

With the engine running and 16 HG at the waste gate actuator I can depress the waste gate actuator rod all the way down with a screw driver with a moderate amount of force. I'm assuming my waste gate actuator is shot? Instead of replacing it would it make more sense to upgrade to a Turbo-Master at this point since at 200K my vacuum pump has a limited life?

Waste-gate solenoid resistance checks out:
20151030_192125_resized.jpg

Waste-gate solenoid harness has voltage:
20151030_193148_resized.jpg

New Waste-gate solenoid (2nd one just to make sure its operational):
20151030_191014_resized.jpg

If I upgrade to a Turbo-Master do I still need to replace the failed waste-gate actuator?
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1997 GMC 3500 Dump 6.5L 2WD
Badger Diesel rebuilt GM8 Turbo
Glowshift Boost Gauge
Heath Diesel Turbo-Master
4" Turbo Back Diamond Eye Exhaust / 2.25" Cross Over Pipe
SS Diesel HD Lift Pump
Bosch Injectors / Duraterm Glow-plugs
Heath Diesel PMD Isolator System
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Old 10-30-2015, 09:24 PM   #7 (permalink)
JMJNet
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Turbo Master replace that rod and pod actuator on the turbo.

You still need to have the solenoid connected electrically and plug the vp if you do not remove it.
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1995 GMC Suburban:
PMD in Bumper
Leroy Diesel Flight System PMD
Leroy Diesel Oil Cooler Line
4" Warpspeed Exhaust
Kennedy Diesel LP/OPS Harness
Bosch Duraterm GP
Heath Turbo-Master
AD244 Alternator

Last edited by JMJNet; 10-30-2015 at 09:25 PM.
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Old 11-09-2015, 08:11 AM   #8 (permalink)
saffron98
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Installed the Turbo Master and discovered that my turbo is seized

1. Where is the best place to purchase USA rebuilt unit?

2. What is the best way to remove the turbo to exhaust manifold bolts? I had a couple of bolts break during the crossover pipe installation -dont want to go through the same thing with the turbo swap.

20151108_164027_resized.jpg

20151108_162851_resized.jpg
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1997 GMC 3500 Dump 6.5L 2WD
Badger Diesel rebuilt GM8 Turbo
Glowshift Boost Gauge
Heath Diesel Turbo-Master
4" Turbo Back Diamond Eye Exhaust / 2.25" Cross Over Pipe
SS Diesel HD Lift Pump
Bosch Injectors / Duraterm Glow-plugs
Heath Diesel PMD Isolator System
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Old 11-09-2015, 08:52 AM   #9 (permalink)
OkDually
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Quote:
Originally Posted by saffron98 View Post
Installed the Turbo Master and discovered that my turbo is seized

1. Where is the best place to purchase USA rebuilt unit?

2. What is the best way to remove the turbo to exhaust manifold bolts? I had a couple of bolts break during the crossover pipe installation -dont want to go through the same thing with the turbo swap.
Give a look at Badger Diesel. Quite a few members have used Badger and have had excellent service..

Catalog Badger Diesel - Diesel Fuel Injection Specialist
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Old 11-09-2015, 02:34 PM   #10 (permalink)
saffron98
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Quote:
Originally Posted by OkDually View Post
Give a look at Badger Diesel. Quite a few members have used Badger and have had excellent service..

Catalog Badger Diesel - Diesel Fuel Injection Specialist
Spoke to Fred -ordered up a rebuilt GM8.

I hear the turbo to exhaust manifold bolts are a bear to take off...any tips on getting them off? Is it possible to remove em without a plasma cutter?

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1997 GMC 3500 Dump 6.5L 2WD
Badger Diesel rebuilt GM8 Turbo
Glowshift Boost Gauge
Heath Diesel Turbo-Master
4" Turbo Back Diamond Eye Exhaust / 2.25" Cross Over Pipe
SS Diesel HD Lift Pump
Bosch Injectors / Duraterm Glow-plugs
Heath Diesel PMD Isolator System
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