Duramax Diesel Variable Turbo Intermittent Issues | P0046, P2563

yeah we're really nailing that exposure setting this is a 2005 Chevy Silverado it's got the Duramax diesel engine you've probably seen it before it belongs to one of my oldest customers the check engine light is on it's got a problem with the turbocharger but the problem is very intermittent this is actually my third time trying to fix it and he's getting tired of bringing it I'm getting tired of seeing it we're going to try one more time and if we can't make heads or tails of it we're going to throw some parts at it it's got a bunch of codes but for now we're going to focus on the p0046 turbo boost control position performance and the p2563 turbo boost control position sensor performance I'm going to ignore the EGR codes and this glow plug code I'm not an expert about durx this is really the only one I ever work on but from my limited experience they seem to have a lot of EGR problems and I've replaced the EGR actuator on this truck twice and I think the problem is it has an aftermarket air filter they use the mass air flow sensor some way to measure EGR flow and they're extremely sensitive to mass air flow sensor performance and the air filter if you don't use the actual GM Factory air filter they will set a check engine light and actually I think I even did a software update to try and fix that and it still still has these codes anyway let's move on so we're going to pull up some data down here for the turbocharger okay so what we're going to do is watch the turbo vein position and then compare it to the turbo vein position command when I start the engine they should be the same so it says desired position is 75 the actual position is 45 keeps raising it there it goes so I think that's the problem is the delay between when the turbocharger you know the sensor actually sees that it moved and when it commanded it to move it should happen right [Music] away see now it's [Music] fine that's it that's pretty much all we have to go on of course a turbo can't just be a turbo anymore it's a variable geometry turbo these things are complicated there's a lot going on in here plus this is all on the exhaust side the hot side of the turbo it's pretty amazing that it actually works the secret is these variable veins they can change their angle to change how the exhaust gas flows past the turbine wheel and they're all connect Ed together by this steel ring called a Unison ring and when the ring rotates it changes the angle of the veins all together and to rotate the Unison ring we use a piston that runs off of engine oil pressure the pressure is controlled by a solenoid here and the position of the Piston is monitored by a position sensor so it's a closed loop system there's a a lot of potential causes for the problem that we're seeing we could have a bad solenoid we could have a bad position sensor we could have a problem in the Piston we could have a problem in the Unison ring or we could have a problem with the veins you know a mechanical problem that stops them from wanting to rotate I don't know how we can possibly test that to determine which component is at fault it's super intermittent it only does it for a very short time on a cold start and after that there's nothing there's no other symptoms if we're going to throw Parts at it that gets expensive very quickly the solenoid is about 250 bucks the position sensor is $450 the internal components they're not that expensive but there's a bit of a problem with access the turbo is back there somewhere maybe you can see it to get it out of there we have to remove the intake tube the charge air cooler tube the glow plug control module the up pipes the downpipe the oil feed line the coolant feed lines possibly the AC compressor and possibly some part of the EGR mechanism the only only thing I know is it's not going to fix itself I tried that twice already so we got to do something we can replace the sensor and the solenoid without pulling the turbo for $700 or whatever but I have a hunch that's not going to solve the problem I suspect it's a mechanical issue with the Unison ring or the veins or maybe the Piston they're built up with carbon or maybe they're just worn out the truck's got $200,000 miles on it but I don't want to pull that turbo out of there on a hunch it's a huge job plus you're talking about a 20-year-old Midwestern truck it's not a question of if we break something it's how many things we break probably a lot but it gets kind of weird I can buy a complete reman Turbo with a new sensor and solenoid for not much more than the price of a sensor and solenoid I don't know how but I can so in my mind that's a no-brainer there's no way I'm going to pull the old turbo out and clean it or do whatever to it and put the old turbo back in that's crazy if he wants that done he can take it somewhere else so I think we're shopping for a remand turbo if only there was a trustworthy source for parts and service of Diesel Injection pumps and turbochargers maybe one who has three convenient locations throughout the Midwest look at this little beauty thanks to our friends at area Diesel service in Carlinville Illinois they can repair or rebuild just about any turbocharger but we actually went for a little upgrade this is not a reman it's a brand new turbo and it is surprisingly affordable I was I couldn't believe it they're a master distributor for Garrett also for Borg Warner they can get you pretty much anything that you want plus they're just good people to deal with I also got an adapter for the sensor which we may not need and a bunch of gaskets and dads for installing the turbo so let's start ripping and tearing get the old one off and stick this little guy on [Music] [Music] [Music] there we go love that wind those things a frustrating mix of is it den and jic so the Japanese Parts use 12 and 14 mm and the American Parts use 13 and 15 mm let's see if we can get this heat don't know if I can get it out of there I'm trying to pull the downpipe so I can get to the back side of the turbo somebody's been here before they stacked up at least four nuts on that v-band clamp and I broke the stud off trying to get the first two off so I don't know what's going on there we may not be able to save that which kind of sucks but I'll do the best I can it's pretty crusty down here okay finally got the down pipe loose it was stuck in the back of the turbo I think it'll come out of there without pulling the heat shield yeah just like I said you definitely have to pull the heat shield to remove the down [Music] pipe oh man that is not fun you got to pull the transmission dip stick heat shield comes out the top downpipe comes out the bottom life goes down the drain okay there's another heat shield on the driver's side up pipe that has to be removed it's got four bolts I only broke two now you won't even be able to see it but I have to unbolt the up pipes from the back of the turbo they're 12 mm 12 point and I got to reach down here and try to break those loose I can't even see them I'm not even going to try to record that and then once I get that done or if I get that done there's a oil drain tube on the bottom that goes kind of kind of down to where the cam is I think this is the supply and that's the drain anyway we're getting close or closer oh man I tell you what somebody had a suu's got a six sense of humor better they never had to work on one of these engines I think it's loose oh yeah we still got coolant lines who designed this freaking thing holy crap there it is nothing to it just pull that turbo right out here's a helpful tip if you want to record a video you do have to push the record button anyway I got the coolant tubes and and the oil drain tube transferred to the new turbo I also went ahead and removed the position sensor and the solenoid just to give us some more room to get the thing installed cuz it is a tight tight fit I also cracked open the old turbo and I think my hunch is confirmed this is the Unison ring right here and it should it should turn freely and it it definitely does not there it is yeah yeah it's all built up with Carbon on that surface it's supposed to rotate on so this fits on the veins like there it is so as it rotates it changes the angle of the veins but in order to do that this little oh leaking everywhere oil this little lever here has to be able to rotate the ring and that is not the case so that's good we made the right call got one more little issue before we install the new turbo our snack stealing friends built themselves a nest down here which is pretty typical got some bedding and some snacks it looks to me like this area was serving as a pantry bedroom and bathroom and they've done quite a bit of peeing on this line that's the oil supply line for the turbo it's kind of crusty also I didn't do it any favors when I was taking the turbo out I kind of tweaked it a little bit which is not designed to do I think you're supposed to pull the EGR cooler so you got room to get this line out of the way which I I didn't do anyway long story short I want to replace that line I don't like it I don't trust it I don't want to ruin a new turbo the problem is this truck's 20 years old this thing is hard to find the local Steelers ship they told me they could get one maybe that would take a week and it would cost $276 which is absolutely insane luckily I found an aftermarket hose that was significantly cheaper and significantly faster so we're going to throw that in real quick I think we're ready got the new oil supply line installed I've got a new gasket for the oil return line this is not a fun job so the biggest problem is well you got to get around this oil supply line but then you also have to sneak that oil return line underneath of the up pipes and attach it onto these studs back here at the back of the engine and really to do this right you're supposed to remove these up pipes but again this is a 20y old truck and we're in Illinois those things aren't going to come off the manifolds without a fight and those are bolts that you do not want to break off and actually if you read the GM official procedure for how to replace this turbo you're supposed to pull the transmission which would make it a lot easier but man that's a lot of work they basically started with a Turbocharger and they built a truck around it okay let's see if we can get it in there I did put this strap on the up pipe to kind of pull it up out of the way you know it's designed to flex oh yeah then we got to stink the gaskets in there ah we'll figure it out the other problem is this turbo it weighs over 50 lbs [Applause] [Applause] okay I'm good okay oh so far so good guess we got gravity on our side yeah that line goes right past the turbo without the solenoid installed I should have thought of that okay not bad now I got to sneak that return line under the up pipe that's no fun well going in is a whole lot easier than coming out let me try to show you guys what I'm working with here there so that is the oil return line it goes right down into the top of the engine those are the up pipes that are going to bolt to the back of the turbo we'll do that next then there's a bracket there for the transmission vent that has to go back on and the up pipe has to go back in and then this bracket for the transmission dipstick has to go back on it is not fun working back here but you can do it the turbo is bolted down the up pipes are bolted up with new gaskets see the drain tube attached there looking good we need to install couple of heat shields and the downpipe and we'll be done with a really nasty part of this job let's get that off there got a new one and you guys can't see those on there [Music] here's the up pipe there it is wait sure it goes back together a lot easier than it comes apart these exhaust flanges are always really Frozen there we go if I knew how to zoom I would zoom in oh I hope you have some good music to go over this be n miles of threads oh man want me to this is the this is the General Motors mechanics children's College tuition fund ain't getting any better than that all right I guess I could do it myself but thanks for the moral support you're welcome I think the worst part of this job might be this glow plug control module bracket there's the bolts down there on the bottom side you can't see them you can't touch them I don't even have a tool that will reach them I can get one click on a ratcheting wrench it's going to take me 20 minutes to install those three bolts well two bolts the one on Top's pretty easy we got some wet cold nasty weather rolling in so it's a good thing we're almost done I got new coolant hoses installed they're just little short jumpers this one was in really bad shape the other one wasn't too bad but I went ahead and replaced them both the GM parts were prohibitively expensive so I just bought a generic Deco elbow I believe the part number is 8 1 0 I am going to need the adapter for for the vein position sensor so I'm glad they suggested that and then really the last thing I've got to do is prelube the turbo so we're just going to stick some oil in here maybe give her a spin we'll hook up the oil line and the air tubes and we should be done with this thing I think we're done just just in time here comes the rain let's see what it does I cleared the codes we're watching the same live data that's what it should do see that it just immediately responded fantastic all right well we'll make sure there's no oil leaks or Cent leaks and we'll we'll call this job done that's it diagnosing removing and replacing the turbocharger on 2005 Silverado 2500 HD with the Duramax diesel engine I believe it's an LL RPO code it's doable but it is not for the faint of heart I believe the the book time is over 12 hours and if the truck's a 20-year-old rust bucket like this one and you're working in your driveway and you've never done one before like I was you ain't going to get it done in 12 hours hours trust me if you have a need for diesel turbochargers injectors injection pumps anything like that check out area Diesel Service I will put a link to their website in the description I just I can't say enough good things about them uh next time we'll be back on the office project I've made progress you just probably can't tell from here so thanks again for watching

Channel: Watch Wes Work

Views: 135,625

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Id: X89gnD4b_X4

Length: 26min 55sec (1615 seconds)

Published: Sun Apr 28 2024