How to change the wastegate solenoid on a 2004 5.9 cummins

Some 2012-2013 Ford Edge and Explorer vehicles equipped with the 2.0L GTDI (gasoline turbocharged direct injection) engine may exhibit DTC P1015 or P1016.
1. Inspect all hoses routed to the turbocharger wastegate regulating valve solenoid for disconnection or damage. Repair as needed.
2. If no hose problem is found, replace the turbocharger wastegate regulating valve solenoid. Torque the two 8 mm retaining bolts to 90 in.-lbs. If equipped, remove the shield covering the filter and discard.
The new turbocharger wastegate regulating valve solenoid is available as P/N CB5Z-9E882-A.

The wastegate has a direct effect on the amount of boost.
Also keep in mind that exhaust restrictions may be affecting it or there may be an adjustment for the wastegate arm. Some have an adjustment and some do not. An Exhaust shop can check your exhaust system for a restriction. Does the "On-Board Diagnostics" show a fault for this issue?
Some info about the vehicle may be helpful.

If you do not know the location of the wastegate solenoid, how could you have properly tested it? Then, if you have not properly tested it, how could you possibly know that it actually needs to be replaced? - (just asking to provoke thought)

Hint: If you are getting a fault code that says "turbocharger wastegate solenoid control circuit" (like maybe a P0243), it would be wise to check the circuit before just throwing parts at the car...the solenoid might not be the problem.

With all that said, the answer to your question is that it is on the other end of the vacuum hose that goes to the waste gate valve - top rear of the engine above the left valve cover.

DTC P0243 - Turbo/Super Charger Wastegate Solenoid A
Description: Open or shorted condition detected in the turbocharger wastegate solenoid control circuit.


Here is the flow chart for that code (some images could need to clicking for zoom)...

P0243-WASTEGATE PRESSURE CONTROL PWM



For a complete wiring diagram Refer to Section 8W.

When Monitored: When the ignition is on.
Set Condition: The ECM detects an open or short circuit in the Wastegate solenoid circuit.

Possible Causes
DAMAGED WIRING HARNESS OR CONNECTORS
WASTEGATE SOLENOID
(F504) FUSED IGNITION SWITCH OUTPUT OPEN
(K139) WASTEGATE SOLENOID DRIVER CIRCUIT OPEN
(K139) WASTEGATE SOLENOID CIRCUIT SHORTED TO GROUND
(K139) WASTEGATE SOLENOID DRIVER SHORTED TO VOLTAGE
(K139) WASTEGATE SOLENOID DRIVER CIRCUIT SHORTED TO ANOTHER CIRCUIT
ECM
INTERMITTENT CONDITION

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

Diagnostic Test
1. DAMAGED WIRING HARNESS OR CONNECTORS



Turn Ignition off.
Disconnect the ECM harness connectors.
Disconnect the Wastegate Solenoid harness connector.

NOTE: Check connectors - Clean/repair as necessary.


Are any wires or pins damaged?

Yes
Repair or replace any damaged wire or connectors.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).

No
Go To 2


2. WASTEGATE SOLENOID



Reconnect the ECM harness connector.
Reconnect the disconnected Wastegate Solenoid harness connector.
Turn the Ignition on, engine not running.
Disconnect the Wastegate Solenoid harness connector.
Connect an incandescent test light across the supply and driver pins at the Wastegate Solenoid harness connector.

NOTE: The ECM will perform a self check of the circuit after approximately 30 seconds, which should light the incandescent test light.


Does the light illuminate brightly after 30 seconds of being connected?

Yes
Replace the Wastegate Solenoid.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).

No
Go To 3


3. (F504) FUSED IGNITION SWITCH OUTPUT OPEN



Connect an test light between the Wastegate Solenoid connector Fused ignition switch output circuit and battery negative.
Compare the test light brightness to that of a direct connection to the battery.

Does the light illuminate brightly?
Yes
Go To 4

No
Repair the open (F504) Fused Ignition switch output circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).



4. (K139) WASTEGATE SOLENOID DRIVER CIRCUIT OPEN



Disconnect the ECM harness connectors.
Measure the resistance of the Wastegate Solenoid driver circuit between the Wastegate Solenoid harness connector and the ECM harness connector.

Is the resistance less than 10 Ohms?
Yes
Go To 5

No
Repair the open (K139) Wastegate Solenoid control circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).


5. (K139) WASTEGATE SOLENOID CIRCUIT SHORTED TO GROUND



Measure the resistance of the (K139) Wastegate Solenoid driver circuit between the Wastegate Solenoid harness connector and battery negative.

Is the resistance less than 10 Ohms?
Yes
Repair the (K139) Wastegate solenoid circuit shorted to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).

No
Go To 6


6. (K139) WASTEGATE SOLENOID DRIVER SHORTED TO VOLTAGE



Measure the voltage between the (K139) Wastegate Solenoid driver circuit at the Wastegate Solenoid connector and battery negative.

Is the voltage less than 1 volt?
Yes
Go To 7

No
Repair the (K139) Wastegate solenoid driver shorted to voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).


7. (K139) WASTEGATE SOLENOID DRIVER CIRCUIT SHORTED TO ANOTHER CIRCUIT



Measure the resistance between the (K139) Wastegate Solenoid driver circuit in the ECM harness connector and all other circuits in the ECM harness connectors.

Is the resistance less than 10 Ohms?
Yes
Repair the (K139) Wastegate solenoid circuit shorted to another circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)


No
Go To8


8. WASTEGATE SOLENOID


Reconnect the ECM harness connector.
Reconnect the disconnected Wastegate Solenoid harness connector.
Turn the Ignition on, engine not running.
Disconnect the Wastegate Solenoid harness connector.
Connect an incandescent test light across the supply and driver pins at the Wastegate Solenoid harness connector.

NOTE: The ECM will perform a self check of the circuit after approximately 30 seconds, which should light the incandescent test light.


Does the light illuminate brightly after 30 seconds of being connected?
Yes
Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure).

No
Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).

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Fault Code 35
Description: Radiator fan relay circuit is open or shorted
Power loss light: Off
Limp-in mode: None

Possible Causes:
Bad connection or wiring - Check the wiring and connections between the logic module and the relay. Clean and regrease any corroded connectors with dielectric grease and repair any shorts.

Bad relay - Disconnect the relay and apply 12V across the coil terminals (between the white wire and either of the other two terminals on the small connector). You should hear a click for either of the two termials and the connection between the grey wire and the other two terminals of the large connector should be shorted.

Diagnostic Method
Trigger Parameters
- Near 0V or near 12V not detected when the relay is turned on or off, respectively
Results If Component Fails
Fault code 35 is stored.


Fault Code 45
Notes: For Turbo models only

Description: Turbo boost limit exceeded
Power loss light: On
Limp-in mode: None

Possible Causes
Vaccum leak - Check all vaccum lines between the wastegate actuator, manifold, and wastegate solenoid. Also check the line to the MAP sensor. Repair or replace any bad lines.

Wastegate solenoid failure - The wastegate solenoid is located in the right, front fender next to one to three other solenoids. See the Understanding Solenoids page.

Bad connection or wiring - Check the wiring and connections between the logic modle (or SMEC) and the wastegate solenoid. Clean and regrease any corroded connectors with dielectric grease and repair any shorts. This condition may be accompanied by a code 36.

Wastegate actuator spring failure - Try to slide the wastegate to wastegate actuator push rod into the actuator. It should not move. Try to pull it out. If it pulls out with little effort (even if it springs back in), replace the actuator.

Jammed wastegate - Disconnect the wastegate actuator pushrod and swing the wastegate arm on top of the turbo. It should have about a 50 degree swing. Make sure the lever and push rod are clear of any obsticles that may cause them to jam (the heat shield below the fuel rail is a major culprit).

Diagnostic Method
Trigger Parameters
- MAP sensor output voltage has exceeded overboost cut-off point



Following years are probably the same as 1987, but I don't have any hard data to back that up. Some have said that 4.74V was the max for Turbo I engines of later years. Some information indicates that the Turbo II with an automatic had a cut-off of 4.96V, but I don't know of any Turbo II vehicle that had an automatic transmission.

Results If Component Fails
A fault code 45 is stored, the power loss light is turned on, and the fuel injectors are shut off. Once the boost has fallen to 3 psi to 5 psi, the fuel injectors are turned back on and the power loss light is turned off. The overboost cut-off point for a particular vehicle depends on the year, engine, and transmission.


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12 Recently disconnected the battery (always stored)
55 End test.

CODE 31... depending on the model, code 31 can refer to two different systems. Please choose from one of the above links for specific information on each system.

Wastegate Solenoid Circuit Error
The ECM regulates turbocharger boost by opening and closing the "wastegate" as necessary. (The wastegate is a vacuum operated bypass valve that limits the ability of the turbo to provide boost.) The Wastegate Solenoid regulates the vacuum supply to the wastegate for proper operation.

Fault Code Description

• 31 - Wastegate Solenoid circuit error

Symptoms

• Lack of power or engine "ping" due to overboost by the turbocharger
  

Common Problems

• The wastegate solenoid would be the most common cause for code 31 to set
• Code 31 does not indicate a problem with the turbocharger or wastegate

Gear Position Switch (PRNDL) Error The Gear Position switch tells the ECM which position the shifter is in. The ECM will use this information to inhibit starter operation, change the transmission shift pattern as necessary, and provide the information for the electronic shift indicator display on the dash.

Fault Code Description

• 31 - Gear Position switch (PRNDL) error

Symptoms

• Engine may not crank over in Park or Neutral
• Electronic shift indicator may flash

Common Problems
A maladjusted or failed Gear Position switch would be the most common cause for a code 31


Hope helps with this (remember rated this post).

P0243 Turbocharger Wastegate Solenoid 1

You can find them all here:

http://www.allpar.com/fix/computer-codes.html

The wastegate is a valve that regulates the ammount of boost that you turbocharger produces. The wastegate opens to release boost pressure.
This valve is electronicly controlled based on inputs to the onboard computer.

Check hose connections at intercooler

Sounds like it's not boosting, and the engine is stopping you from doing damage - check the wastegate modulator (solenoid on the side of the engine in front of the turbo and under the air intake pipe). Also check that the breather hose has not worn through the wastegate actuator causing a vent to atmosphere. If these are fine, then you may have a vacuum problem - are the brakes ok?