frmll300

I tried out a 96 w/a 5spd today . Has a few issues ,first of all it requires some pressure on the accelerator to get it to start and then idles fine .Second the fuel gauge isn't working .And most importantly the turbo doesn't kick in till about 2050 rpm.The vacuum line on the waste gate on this one is connected to something at the back of the inj. pump (sorry my experience is with first gen)Should you be able to move the wastegate rod?It wont move by pulling on it. When you get the truck running over 2100 travelling on the road there seems to be a loud hiss of air somewhere,but when idling you don't here any air leaks. the truck has a boost gauge at idle it shows no boost what so ever at 2100 it shows 10lbs and at 2700 it shows 15lbs.Any suggestions would be appreciated.Thanks

Box5

my fuel gauge doesn't work either, it's the sending unit in the tank ($45). Your in a colder climate so it might need some fuel to start, but when it's warm you shouldn't need any pedal. Sounds like it's got a nice boost leak, probably a loose hose somewhere, that would be a reason for the low boost, because it should boost way before then. It might be worth it to do the water test, and put some water on the hose connections to see if any bubbles form from a leak.

Box5

Your testing the boost under load right? As far as the wastgate goes, i can't help because mine has a banks wastgate on it, the line going to the pump is correct, same on all of them....

frmll300

Thanks Box5.To do the water test are you suggesting that the hoses could be pourous or that the bubbles would be forming from air escaping between the hose and the pipe? As far as the starting it was about 38 * F here today,and even after driving for 15 minutes on restart it requires the same .Sorry I didn't include this info before

frmll300

When trying to diagnose the prroblem we also look at another '96 but it's line seemed to only run to the compressor side of tubo.

WildBill

Idle adjust, replace blown intercooler boot (probably the lower one on the passenger side)

somis13

DONT KEEP DRIVING IT! do you have a pyro guage? mine made that noise when I blew the lower passenger side inter-cooler boot off. the E.G.T. went up to 1400 at that point. I think it definitely has a boost leak. and it should be very tough to function the waste gate by hand.

Box5

Yea, a pyro gauge would be great to see whats going on, because EGT's are very sensitive to throttle and load etc, they can be at 300F one second, and you hit a hill and accell and they'll be to 900 in a couple seconds, so like he said it's probably not smart to drive it unless you know it doesn't have a leak.

The water test is just to see if bubbles will form from a leak so it's easier to find, but all ur symptoms = boost leak, really easy fix once you find the hose connection thats leaking.

realtreehunter

it would be better to mix some water and dishsoap so you will see the bubbles better so just mix it in an old hair spray bottle or something and spray it on the boots

frmll300

Thought I'd give an update, I bought the 96 got it home and discovered a hole in the fins in the air con rad and thought imight look behind that at the intercooler and guess what ? There is a 1" long hole in one tube on the intercooler.The dealer I bought it from wouldn't believe me when I would tell him where the air was escaping. Oh well I bought it prepared for this .Where's the best place to get a replacement intercooler?

Lil Dog

PDR has intercoolers for a pretty decent price, baring in mind that they also sell a plate and fin style to upgrade to. Other than that its tough to find unless you go to BANK$...

Box5

Or if u just want a OEM replacement, check the junkyards, or ebay.

Lil Dog

I was looking around the junk yards in my area last year and they didn't have much. Animal contacts seem to be the primary write-off and they are first in line to be mangled..