c-16 low power since rebuild

My Dad owns a 2003 c16 Cat in a logging truck
last winter the head cracked in #6 exhaust port
Kenworth installed a new head, 2 weeks later the turbo expired we installed a Cat reman turbo
then shortly after decided to install new injectors as preventitive maintence thinking a dropped tip could ruin the new head and turbo we just had installed $$$$ no warrenty left on this engine

after installing the injectors the truck ran terrible but only after working it hard for about 15 mins then parking it and idling it at high idle
finning ran the truck on the dyno and after several sets of injectors got the engine to run decent again

400hrs after the head had been installed the truck started pushing coolant out the overflow
im a journeyman mechanic at Peterbilt and this time took it apart my self
#1 liner flange was cracked and we decided to put in 6 new cylinder kits

as soon as he started using the truck again after this last go around
its seems down on power
the boost used to be quite responsive and would go to about 35 on the gauge with a fuel wire and messing with the wastegate a bit before
now it hits about 32
ive checked for boost leaks
reset the valves and injectors twice (the last time I used a dial indicator just to make sure it was perfect)

my question is
the timing calibrated on the first try after the rebuild with no adjustment needed on the idler below the Cam gear
but if it was on the highside of the 4 degree window before and now on the low side would that be noticable
ive rebuilt many Cat engines and this is the first one that seems weak

any timing calibration information would be greatfully appreciated
im a hot rod Diesel kinda guy at heart and want this thing to run perfect

thanks Austin

 

I did check the injector trim codes originaly they were set to 6999 but we put them back to stock after a while after reading some information on trim codes on this forum (but it still seemed weak before we cut it back)
the fuel settings were deffinitly not messed with
we went with Cat Reman piston packs i forget the part number right now but i looked into it a bit and as far as i could see there was only one available (that doesnt mean i missed somthing are there different ones?)
i didnt take the packs apart and check .......i should have though but the blowby seems fine
I set the valves to .015 and .030 the Jakes i ususally set on the high side of the spec .040 on that engine 7cz03457
ive heard of setting the intake valves tight before and tried it but didnt notice a difference i set them to .013 the time we tried it .......... how tight do you set them ??
we are getting 20psi on the Jake and the boost only seems slow to build and coming up short on the power 32 instead of the 35 we used to get
i checked the gauge by putting a T in the line and using another gauge and it was pretty close to the same within 1psi
fuel pressure is bang on ive installed a big liquid filled gauge and left it in place
and the Cam is still the original
i removed the head with the turbo and exhaust manifold attached and never split that part apart so i was assuming that part would be ok still

Thank You to you both for the ideas here
i think ill check the Cam sensors and make sure they are both working just incase
and double check the Backlash i checked it when i put it togeather before i had the rockers on and im sure i set it to .006....... the timing did calibrate at .006 so i guess that kinda rules out the cam sensor not working theory

any more tips ?????

Thanks again

 

we checked the fuel pressure, its bang on we replaced the fuel pump with a NEW cat pump anyway just because, we also replaced the pressure relief valve in the filter head just because....... no change in fuel pressure or performance
the sleeves are deffinitly good we have since replaced the manifold because it was leaking at the expansion joints
checked the wastegate with a dial indicator and it was within stock specs but shimed the pot with a couple 1/4 inch washers to make it a little tighter which made a difference of about 2psi on the Jake
Checked Boost leaks and found none...... all the boots for the air to air are double clamped now just because
ive made sure the throttle is going to the floor and clear but didnt have a laptop to check if the ECM is seeing 100% thats a good idea ill look into that !

there was a difference when we took the 6999's out but I wouldnt say it was outrageous
it was about a half a gear difference
we are up in Canada in the interior of BC
about 8 hrs of driving from the closest US Border crossing but thankyou very much for the offer Far Call
right now im back at work 400k away from the truck next time im up there ill be checkin throttle position
and im going to split the turbo and check the turbine wheel

 

Far Call what do you think of running 6999's with these injectors
1) 6846
2) 7615
3)1872
4)2865
5)2642
6)3747
we took out the 6999 because these numbers seem so unmatched after reading another post on this forum
on the same note he hauls logs in steep country and is hauling around 61000Kgs when bundled right out
so we would like to see some decent power out of this thing