Replaced turbo revs in idle fine
When in gear at 2200-2500 rpm no power and engine makes a loud racket

Something still isn't right, check your Hoses and intercooler connections.

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Silver 2006 KJ 2.8L CRD Limited:
GDE ECO Tune / Fumoto Valve / E-Tecno GX3123 7v Glow Plugs / 2nd Gen Fuel Head / Mishimoto RED Hoses / Rockers/Lifters @ 114k / Hayden FC + 11 Blade Nylon / Sears P1 Battery / Transgo 45RFE-HD2 Reprogramming Kit / Timken Front Bearings

Is that the second rebuilt turbo per the discussion at viewtopic.php?f=5&t=77000&p=808250#p808250 ? If so more details on what type of racket? Possibly an install issue like hoses or some such but I'd suspect the turbo.

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Sold to LOST member my 05 Ltd, GDE Stg II turbo + TCM tune, SunCoast TC w. Transgo kit, Steiger window regulators, Samcos, Fumoto valve, 2nd gen filter head with Lub. Spec. bleeder, Hayden clutch & 11 blade fan, inverted spare, P-1 battery, BF Goodrich Long Trail TAs, Etecno1 glow plugs, timing belt at 50K miles/8 yrs

One thing that would help if it threw a code ....
Checked all of the hoses.... All tight but they are original equipment

And it is the 2nd turbo from the other discussion

How do I know if the 2nd turbo is bad ??
Any input would help
Thanks jon

Here is a picture of a bad turbo. Notice the damage to the vanes:


Here is a picture of a good turbo. Notice the difference:


A bad turbo will have a lot of play in the cartridge, which results in the vanes contacting the housing. This play will allow oil to be sucked into the intake instead of flowing to the return line. The combination of oil being sucked in as well as the lower boost level results in black smoke coming out of the exhaust.

I had a turbo on an excavator with too tight of tolerance to the housing. The excavator was sitting outside for an extended period of time and rainwater caused a little rust in the turbo. This prevented the cartridge from spinning and also resulted in a lot of smoke due to low boost (lack of air).

Smoke can be due to a lack of air (low boost). Low boost can be a bad turbo, but can also be caused by leaks in the piping from the turbo to the intake. A pressure test can be performed. Take a plastic cap and drill a hole in it. Insert a tire valve into the hole. Put this one in the hose at the turbo. Secure with a hose clamp. Put another solid cap in the hose at the intake (flow control valve end) and secure with a clamp. Add a little pressure and listen for leaks.

Smoke could also be caused by a broken rocker on the intake side. The cylinder with a broken rocker cannot get enough air to mix with the fuel. This results in unburnt fuel (smoke).

Could also be caused by a stuck egr valve. This allows exhaust back into the intake, which lowers the amount oxygen available and again results in unburnt fuel (smoke).

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My collection of CRD's:
2005 Deep Beryl Green Pearlcoat
2006 Light Khaki Metallic Clearcoat
2006 Inferno Red Crystal Pearlcoat
2006 Midnight Blue Pearlcoat
2006 Gold Limited
2015 Black Ecodiesel
2015 Black Ecodiesel 2

A lot of people, Myself included a while back, have assumed that a broken rocker/lifter was a bad turbo, and have replaced it (even with a brand new turbo) just to find out the problem still existed.

First things first, get yourself a brand new turbo, these (according to the manufacturer) cannot be rebuilt as you've already been informed, despite what the company taking your money is telling you.

Once you have put a brand new turbo in, you have taken that out of the equation. (most likely anyway)

Now if it's still running rough, you check your CAC hose and intercooler hoses to ensure they are in good condition, and then you check your boost pressure solenoid to ensure it's not another type of turbo issue.

_________________
Silver 2006 KJ 2.8L CRD Limited:
GDE ECO Tune / Fumoto Valve / E-Tecno GX3123 7v Glow Plugs / 2nd Gen Fuel Head / Mishimoto RED Hoses / Rockers/Lifters @ 114k / Hayden FC + 11 Blade Nylon / Sears P1 Battery / Transgo 45RFE-HD2 Reprogramming Kit / Timken Front Bearings

A NEW turbo is on its way.... It will be here tomorrow morning
I will update once installed
Thanks again for the input it is greatly appreciated
Jon

More info on testing for leaks. Here is a picture of some of the hardware store items you might use to plug the hose ends:







You can also test your boost pressure by placing a tee inline and hooking a pressure gauge (0-30 psi) to the tee.

_________________
My collection of CRD's:
2005 Deep Beryl Green Pearlcoat
2006 Light Khaki Metallic Clearcoat
2006 Inferno Red Crystal Pearlcoat
2006 Midnight Blue Pearlcoat
2006 Gold Limited
2015 Black Ecodiesel
2015 Black Ecodiesel 2

Jon sent me a picture of his turbo. I'm 99% sure it is toast. Here is the picture:

_________________
My collection of CRD's:
2005 Deep Beryl Green Pearlcoat
2006 Light Khaki Metallic Clearcoat
2006 Inferno Red Crystal Pearlcoat
2006 Midnight Blue Pearlcoat
2006 Gold Limited
2015 Black Ecodiesel
2015 Black Ecodiesel 2

How did the vanes get chewed up like that? A torn, rotted intake hose?

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TWO Identical 2005 Liberty Sport CRDS
#1 CRD, 174,000 miles. Eco tune, Samco hoses. Mobil1 0-40w used since day one
#2 CRD 143,000 miles. Bought used (unknown history) with 100,000 miles. Samco hoses.
Eco tune, new rockers, and 5 volt glow plugs installed at 124,000 miles