HELP: Cleaned Inlet manifold, intercooler and now buckets of smoke....

[Hoopsville Lurker Find all posts View Profile Close Hoopsville]

Hi All,
Member for a little while - reading, reading, but first post
Decided to clean the inlet manifold of my 04 Grand TD w 215,000Km on it after reading a few post on PP. Economy had been dropping but otherwise running like a dream. Inlet was filthy w carbon buildup!!!! Thin oil film inside the intercooler so washed out the intercooler and the vertical metal pipe between turbo and intercooler with petrol a few times. Left both for about an hour, then reinstalled.
Startup OK, then after a 1/2 minute slight exhaust smoke. THought it was just a burn off but drove for about 3-4 minutes and it got worse ++. Plumes of the stuff.
Dismantled and found a fair bit of oil in the intercooler, inlet manifold, vertical pipe and can even see some pooling in the outflow side of the turbo.....:-((
Your thoughts? Anyone experienced similar??
Could it be residual oil laden petrol hiding in the intercooler? Would it go back in the system and down to the turbo.
Surely there is no way i've blown seals in the turbo...
Do I have to remove the turbo to get the oil pooling in the exhaust side out or is there enough clearance from the fins to carefully mop it up w a rag if i just insert it straight down. How can I check if its the turbo seals??
Thanks in advance guys...

[Hoopsville Lurker Find all posts View Profile Close Hoopsville]

Solved

Hi All,
Problem solvered.
I'd blocked the crankcase ventilation pipe (don't ask) and the increase crankcase pressure had forced oil past turbo seals and flooded the intake system.
Vacuumed (wet and dry) the oil out the turbo carefully using a plastic drinking straw and a rag to seal the vacuum wand end.
re-cleaned the intercooler, vertical pipe and throttle body.
Took 10 mins for the residual oil to move thru the system and burn off.
20 min drive of suburb + a bit of 80kph + serious giving it the stick and onboard computer = 11.6l/100 Average - before i was pulling 13.7-14.7l/100 Average.
Early days but looks good.
I will report back.
Cheers

[adrian5800 Advanced Member Find all posts View Profile Close adrian5800]

Your lucky, I have seen two diesel engines run away on oil. One was a Scania that sounded like it was reving at twice the red line with flames shooting out of the exhaust (it held together) and the other one was a Gardner straight 8 on a test bench. That one threw a rod out the side...

Moral of the story is always clean every skerrick of oil from the intake of diesels when you do repairs such as turbo replacement when they have let go.

And I have to ask, how the hell did you block the breather?

Ades