Today, my CRD threw P0234 and P0102, turbo over boost and mass airflow low error codes. MIL light, limp in mode, lack of power, enormous clouds of blue smoke, 20 feet high at idle, lots more at take off, clears on higher speeds. Oil level dropped nearly a quart in 3 days, no leaks, but inside of turbo hose from turbo to intercooler, which was cleaned a short while ago, is loaded and dripping with engine oil, oil dripping from intercooler inlet pipe also. Provent has very little oil in it, and output from provent to turbo is clean and dry. No oil leaks anywhere on the engine top, sides or bottom. Except for sluggish power, engine runs good, but smoke is annoying to say the least. Exhaust smells like burning motor oil. 20K miles.

Has anyone else had a turbo throw a code and blast engine oil into the intake?

Air filter is 4 weeks old, clean. I've seen RFRD's post on excessive oil getting into his CRD's intercooler and intake, but I haven't found any posts by searching, where the P0234 code was set, MIL lit and limp in occuring, all with massive amounts of blue oil smoke and heavy engine oil loss. Coolant is clean and correct level. No unusual noise from engine mechanicals. Engine sounds smooth, runs good, just very slow when not in limp-in mode. Seems to go in and out of limp in mode. You can tell when limp in mode happens - no engine rpm above idle when accelerator is floored.

I'm thinking out loud here - If the air flow valve did malfunction and stick closed, I can see where the boost might spike, even to 75 psi, possibly blowing the turbo oil seals, but you would think the PCM would sense the boost spike and send command signal to the vgt vanes to back off. But, if the air flow valve was stuck shut, even briefly, it would still build too much boost even with the vanes set for minumum boost.

Man these vehicles need a standard boost gauge. That would help considerably when boost problems happen. If I hadn't been able to pul the freeze frame data, there is no way I would have even suspected excessive boost.

If the egr air flow valve malfunctions, closes while full boost is on, I could see spikes happening. I'm wondering if the VGT vanes can really respond fast enough, being vacuum activated, if the air valve closes while under high boost - if the boost spike lasted even a second or two, it might be enough to weaken the turbo seals. Especially if the air flow valve fails intermittently on a onging basis, overpressurizing the seals over time. Man these vehicles need a standard boost gauge. That would help considerably when boost problems happen. If I hadn't been able to pul the freeze frame data, there is no way I would have even suspected excessive boost.

there must already be a boost sensor

Checked the play on the compressor - vertically I can't detect any. Horizontal play, is a good 3/16". Compressor blades are in very good shape. No visible signs of damage. The compressor spins freely without noise - but it does have what seems like excessive horizontal end to end movement. In fact, when running the engine, you can hear the turbo whine and it sounds normal.

Over on the engine intake, the case of the egr air flow valve is weeping oil on the top surface, at the seam where the outer cover joins the main body. Not surprising with the amount of oil loss.

A thorough inspection of the engine pan, transmission to engine seams and anywhere else oil might be leaking comes up dry. Coolant is clean, but oil in the hoses is way over any normal amount. It's liquid engine oil in both hoses.

I'm done inspecting - its going back for repair.

Yes, excessive end to end play, but almost no vertical slop. Spins freely when turned by hand.

Oil consumption - it just started in the last week, along with the blue exhaust smoking - hard to tell other than its losing a quart every ~ 3 days or approximately 200 miles. I've been on the road this last week and I check the oil level at each fuel up. Friday a week ago, it was on the max mark - by Tuesday, it was down to Min on the dipstick. Added a quart and it came back to just on the Max mark. By this past Friday, it was down to the Min mark again. Oil measured when hot, after waiting 5 minutes past engine shutdown. Topped off today and it took exactly one quart to bring it very close to the Max mark again.

I also disconnected the turbo hose from the intercooler at the front of the vehicle on the passenger side, then started the engine. If I rev the engine to 1200 rpm it blows oil 20 feet from the end of the turbo hose - a lot of oil. No doubt where the oil is coming from. Spent all morning cleaning the driveway up.

Blown turbo. Your thrust bearing is toast. That could be a result of faulty air flow valve (and no pop off valve for safety). When you lose your thrust bearing it becomes imposable for the turbine side seal to make a good carbon seal anymore. So as pressurized oil is pumped into the top of you bearing housing, some of it is pumping right into the turbine housing and burning off.