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 Post subject: Turbo Troubles and Tribulations
PostPosted: Sat Dec 14, 2019 7:08 pm 
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Joined: Fri Aug 13, 2010 11:14 pm
Posts: 27
Location: Collinsville, IL
This may be good for a variety of turbo's, not just CRD.
The CRD has 300,000 miles on it and the boost hoses had some oil in them.
I figured the oil seals were getting tired and I'd swap the turbo.
I got one from Sasquatch and put it in.
It takes 6 hours no matter how hard you try to do it faster.
I know, i've done it 3 times.
I read the instructions in the manual first, then read everything I could find on putting turbo's in.
nothing I read prepared me for this.
The only "TRICK" I found was after you put the drain pipe on and before you put the input oil banjo bolt in, pour some 50 or 60 weight down the hole.
I also use new copper clad pinch bolts on the turbo studs each time.

The first Turbo caused a lot of black smoke when I got on it.
I trouble shot it and found the vacuum didn't start pulling the vanes up until 15 lbs of vacuum.
My old turbo started at 5 lbs of vacuum.
Moral: Check the vacuum on the turbo before you put it in.

The second turbo I got checked very carefully inspecting in and testing the vacuum.
I put it on and immediately there was gray smoke.
I pulled it out of the garage and there was a LOT of gray smoke and getting worse.
I pulled it back in and pulled the boost hose on the passenger side, it was FULL of oil.
I pulled the drivers side and it had some, but not a lot.
I checked the oil level and it was down a quart.
that means there's quite a bit of oil in the Inner Cooler.
I pulled the inner cooler and rinsed it with diesel fuel, followed by gas followed by a large bottle of dawn soap followed by a LOT of water followed by 2 bottles of isopropyl alcohol to absorb the water.
Then I blew the thing out for an hour with my motorcycle air squeegee.
That got quite a bit of thick, tarry oil out, which i suspect was a build-up from the original turbo leaking.
I pulled the second turbo and there was oil on both the exhaust side and the boost side, so someone forgot to put the oil seals on when it was built, or put them on with the gap in the wrong place..
Moral: If you see ANY gray smoke after putting on a new turbo, shut it down IMMEDIATELY.

I just put the third turbo on.
it fired up and idled well.
I checked for leaks and took it for a ride.
it started blowing gray smoke about a block from home.
I immediately went home.
I pulled the boost hoses, they were dry!!!!
I checked the bottom of the turbo, there is some oil on it.
I checked the input oil line and it's clean.
I pulled the output oil line and the gasket is in good shape and positioned well.
Next I'm going to pull the exhaust to see if it's oily.
BUT! When I put the exhaust on, i thought it was a good idea to flip the clamp to face up.
Now I have to take everything on top off to get to it.
The moral so far is don't overthink what the engineers did.

Update to come in a few hours.

_________________
06 Liberty CRD Sport
AMSOIL
Metal Glow Plugs
Fumoto valve
Samco
PML Tran Pan
GDE Eco Tune
Euro TC
Sasquatch Provent
EGR Delete
Weeks 101 Elbow
In-tank Lift Pump
Sasquatch airbox-to-turbo hose


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 Post subject: Re: Turbo Troubles and Tribulations
PostPosted: Sat Dec 14, 2019 7:48 pm 
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LOST Newbie

Joined: Fri Aug 13, 2010 11:14 pm
Posts: 27
Location: Collinsville, IL
An hour later.
The exhaust turbine looks fine, so the gray smoke is from left over oil in the intake from the 2nd turbo.

The leak must have come from the drain pipe gasket.
I'm going to deck the bracket and use copper sealant to put it back on.

_________________
06 Liberty CRD Sport
AMSOIL
Metal Glow Plugs
Fumoto valve
Samco
PML Tran Pan
GDE Eco Tune
Euro TC
Sasquatch Provent
EGR Delete
Weeks 101 Elbow
In-tank Lift Pump
Sasquatch airbox-to-turbo hose


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 Profile  
 
 Post subject: Re: Turbo Troubles and Tribulations
PostPosted: Wed Dec 18, 2019 12:25 pm 
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Joined: Fri Jun 22, 2007 11:43 am
Posts: 4958
Location: Green Cove Springs FL
Are you sure the original turbo is bad?
Generally, the test is to try to wiggle the impeller shaft. Shouldn't wiggle at all.

The oil you were seeing in the CAC hoses was most likely from the crankcase vent.
Have you replaced the turbo inlet hose?
The oil from the crankcase vent usually causes the inlet hose to deteriorate and tear when you try to remove it.
Most install a Provent to trap that oil before getting to the turbo inlet.

Dont know what to say about your replacement turbos other than many rebuilt turbos are crap.

Congratulation on getting to 300k miles without significant engine problems.
You should share your experiences and all the things you've done right with it.

I'm at about 230k miles. Still factory turbo and I have a Provent installed.
The Provent doesn't trap all the oil but does a pretty good job. Still get some oil in my CAC tubes.
I've recently replaced my leaking intercooler. There was about a pint of oil in it.

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U.S. Army Retired


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 Post subject: Re: Turbo Troubles and Tribulations
PostPosted: Mon Aug 09, 2021 4:59 pm 
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Joined: Sat May 29, 2021 7:59 am
Posts: 61
Location: Central Minnesota
What did you ever find out about the turbos?? I was looking at a Sasquatch turbo, that is why I am wondering.

_________________
2005 KJ Crd Used to own in 2014.. bought back again in 2021
Sasquatch battery tray
Cummins lift pump
GDE Eco tune and trans tune
Samco intercooler hoses
Rocky Road lift w/Toyo 245/75/16

05 CRD swap underway into 76 FJ40


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 Post subject: Re: Turbo Troubles and Tribulations
PostPosted: Wed Aug 11, 2021 4:32 pm 
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Joined: Sat Apr 17, 2010 3:29 pm
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 Post subject: Re: Turbo Troubles and Tribulations
PostPosted: Thu Oct 14, 2021 4:14 pm 
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Joined: Mon Aug 30, 2021 12:34 pm
Posts: 2
fjdiesel wrote:
What did you ever find out about the turbos?? I was looking at a Sasquatch turbo, that is why I am wondering.


We just put a replacement Turbo, vacuum solenoids, intake hose and intercooler hoses on from sasquatch. We've put about 200 miles on it with no issues.


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 Post subject: Re: Turbo Troubles and Tribulations
PostPosted: Mon Oct 18, 2021 10:02 am 
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Joined: Sat May 29, 2021 7:59 am
Posts: 61
Location: Central Minnesota
BIG PHIL wrote:
fjdiesel wrote:
What did you ever find out about the turbos?? I was looking at a Sasquatch turbo, that is why I am wondering.


We just put a replacement Turbo, vacuum solenoids, intake hose and intercooler hoses on from sasquatch. We've put about 200 miles on it with no issues.



Good to hear!! Because I wanted to order one of those turbos from Sasquatch. Keep us posted if anything comes up. Thanks.

_________________
2005 KJ Crd Used to own in 2014.. bought back again in 2021
Sasquatch battery tray
Cummins lift pump
GDE Eco tune and trans tune
Samco intercooler hoses
Rocky Road lift w/Toyo 245/75/16

05 CRD swap underway into 76 FJ40


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 Post subject: Re: Turbo Troubles and Tribulations
PostPosted: Mon Oct 18, 2021 9:33 pm 
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Joined: Fri Jun 09, 2006 2:30 pm
Posts: 2505
Location: LOST in Wisconsin
I just installed a Sasquatch turbo. So far so good. no issues with smoke. It spools up nicely. I threw a P1252 right after I install it. Reseated all the vacuum hoses and so far it hasn't occurred again.

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2005 CRD "Ol' Blue"
Red Ryder carbine-action, two hundred shot range model air rifle with a compass in the stock and this thing which tells time.
My build page- RL Komodo Rear and TJM Front Bumper, armored, lifted, JBA Steel D30, 4.10s and ARB air lockers.


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