Peeps,

Rockers / lifters are replaced. Engine is back together. She starts, she runs. But she not runna so good. Flushed out intercooler well. Put everything back together, still no runna so good. Pulled off intercooler again, GOOP AND OIL IN IT AGAIN!. Cleaned again. Still no runna good.

We are going to check the oil return house to see if we have a block.

What could be the other reasons for continuing to get oil into the intercooler from the turbo?

Please Advise.

~M~

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'06 Khaki Jeep Liberty CRD
65,000 miles
2nd Gen. Fuel Head, 2nd Turbo Charger, 2nd Timing Belt, Reman HD TC, EHM, GDE Full Torque Eco-Tune, 7v Etecno GPs
Blue Samco hoses, because I want people to say, "Here's a guys who knows what he's after."
MAP sensor: clean.
As soon as the CRD reached the limit of the warranty, CEL went on.

Some questions to help the helpers:

Did it run Ok before you tore it down?

How much oil is making it into the turbo outlet hose and intercooler? The 'normal' amount can be surprisingly significant..

Any CEL codes?

You may have vacuum leaks,
or perhaps air in the high-pressure lines to the injectors - any signs of fuel leaks around the injectors?
Could the timing belt be off a tooth?
Might you have knocked a few lifters off when re-installing the engine cover?
Any issues during the re-install that may give us a clue? You know, the ones in the back of your mind... ; ' )
Stock fuel system, or do you have a lift-pump?

Have you run the engine long, or taken a test drive yet?

Mark

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2005 Liberty CRD
2004.5 Cummins 5.9L TD, F1s, NV5600 6-speed in a '93 GMC Suburban

The only 2 sources of oil that I know of (cannot speak for goop whatever that is) in the intercooler are 1) oil from the turbo itself which would likely translate to blown internal turbo seals and I suspect virtually instant obvious turbo failure or 2) oil from the CCV down the line to the airbox to turbo hose right in front of the turbo thru the turbo to the intercooler.

I suspect the latter so maybe pull that airbox to turbo hose and clean it; do same for hose to intercooler; flush intercooler again if that seems like it needs doing; do at least temporary elephant hose mode to send CCV oil somewhere other than turbo. If that solves your oil and/or goop in intercooler then I'd suspect a defective CCV valve is letting excess oil into the turbo system. Alternatively I suppose, way out on limb here, it might be possible that the engine is somehow generating excess crankcase pressure that's shooting excess oil thru the CCV. If so maybe??? you could remove the oil filler cap and see what kind of back pressure comes out of it. Be kind of careful doing this as 1) if the engine is hot the oil will obviously be hot and 2) I seem to recall a post that it's normal for a certain amount of oil to spray out if the filler cap is off so use a disposable towel of some sort to keep the mess off your engine.

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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

Quick summary:

Had a turbo charger failure. Drove it 1.5 miles after failure. Had to pull two hills to get to where I could park it. The high RPM's of those two pulls backed the flexplate bolts out, ruined the flexplate hub, the tming belt jumped four teeth and it crushed all lifters on the exhaust side of engine, . The engine started a few times during early diagnostics. We then went ahead and replaced flexplate, hub, bolts, torque converter (update-might as well), transmission seal, turbo charger, turbo oil return line (pinhole), and timing belt. We replaced all washers/rings for injectors, and replaced all of the rocker/lifter sets on the exhaust side.

Jeep starts. Jeep runs on it's own power, but doesn't run top. It's at my mechanics. Only code I know of is our old trusty friend, "EGR Low-flow".

There's enough oil getting into intercooler that the mechanic is saying, "wow, that's a lot."

No fuel leaks around injectors as we just dressed them up for the prom.

No lift pump. Fuel delivery / fuel system is fine.

Every system in this Jeep has been given every look and every test known to man. This is month 6 of it being in the shop.

It's probably going to end up being something stupid at this point. I wouldn't be surprised if some lifters were knocked around.

I am awaiting the latest update from service manager.

Lots of waiting. Only one diesel guy at the shop, with multiple diesels going on at all times.

Thanks for the stimulation of questions.

_________________
'06 Khaki Jeep Liberty CRD
65,000 miles
2nd Gen. Fuel Head, 2nd Turbo Charger, 2nd Timing Belt, Reman HD TC, EHM, GDE Full Torque Eco-Tune, 7v Etecno GPs
Blue Samco hoses, because I want people to say, "Here's a guys who knows what he's after."
MAP sensor: clean.
As soon as the CRD reached the limit of the warranty, CEL went on.

As always Papa, Thanks for the time and thoughts.

The turbo was just replaced. (see reply above for full summary). Waiting to hear back from Service Manager. If they haven't looked into CCV test, I will let him know.

_________________
'06 Khaki Jeep Liberty CRD
65,000 miles
2nd Gen. Fuel Head, 2nd Turbo Charger, 2nd Timing Belt, Reman HD TC, EHM, GDE Full Torque Eco-Tune, 7v Etecno GPs
Blue Samco hoses, because I want people to say, "Here's a guys who knows what he's after."
MAP sensor: clean.
As soon as the CRD reached the limit of the warranty, CEL went on.