Gentlemen, Exhaust smoked intermittent at idle and then on hills and then just started about full time over course of weeks. This information courtesy of the driver. In the shop we saw the wet oil stain on exhaust pipe behind turbo. Pulled intake and have excessive thrust play back and forth, about 1/4” This engine has been overhauled twice and has the same turbo since we purchased in 2015. Curious of people’s opinion on the manifold condition, and if we should replace it along with the turbo? Also curious if we are missing something else to do here. Much appreciation for suggestions.
Turbos have a life span, although it can vary widely and not necessarily with type of engine. It wore out. If there are no broken exhaust manifold mounting bolts to head and no visible exhaust leaks at head ports, plus turbo mounting flange is ok, leave it. But change oil and change filter, because there just might be metal particles in oil pan. And expect to find some with first few oil changes. Make sure and pre-lube new turbocharger before install. I usually have another person fire the engine, bring it to normal oil pressure {while I have a long blade screw driver inserted in air intake compressor wheel {locking it so it can't turn till screwdriver is quickly removed after 10 seconds of run time. That way I know oil has reached the turbo before it spins}. Much less issues that way. * Oh--make sure and clean air intake tube and change air filter, metal particles can make their way back the other direction, and don't want suck crap into new turbo. Clean drain tube also.
Ill prelube the turbo or the whole engine on a fresh rebuild but have never thought of locking the turbo down. I like that idea I'm going to borrow that one.
Thank you for the reply Truck Shop. Truck is back on the road. $1200 borg Warner turbo. Local shop clocked it for us using old turbo as jig. No charge. $6 pack of serrated flanged 1.25 grade 8 nuts. New air cleaner $60, new oil $150 and filter $25. Found 3 pieces of a ring pictured below on oil pan magnet. Hope thats from turbo and not something else. Cleaned intake tube and housing, oil drain line and air cooler tube. Filled turbo with clean oil, unplugged the cam sensor and locked turbo still and cranked until we had oil coming from inlet line. Connected and then cranked until draining from turbo outlet. Connected line, cam sensor and air cleaner. Fired right up. Driver says no smoke, more power and sounds smoother. Thanks again Truck Shop for your comments.
Your welcome.