300 tdi excessive white smoke and oil leaks

[Challo]

Help required please,

1996 300tdi defender.

Last week had a bad rattle off idle that worsened as revs increased.

Also a scraping under load/ boost.

Rattle sounded to come from head/ timing casing but not 100%.

Changed head gasket and timing casing gaskets, pulleys, idlers, belt last spring and that's been fine since.

The scraping to me sounded like the turbo shaft bearing had collapsed causing it to grind on the housing.

Managed to get a secondhand turbo and have installed that this weekend with new feed and return pipes.

Primed turbo with oil.

Also removed intercooler and all pipes, swilled out with petrol then blown out with air line.

Also removed injectors, cleaned then and fitted with new seals.

Right took it for a spin and its absolutely billowing massive clouds of white smoke and turbo is whistling under load/boost.

Came home n checked all hoses and took it for another spin.

Same.

So I had a proper look with engine off and running.

Tail pipe has a coating of oil.

Oil is dribbling out of sump which didn't before and pretty fast.

Fair bit of oil at back of block deck, cylinder 4.

Oil bubbling from around top of cyclone breather.

Worst of all, oil dribbling down studs and flange of down pipe but no sign of oil above, on the turbo.

So I am thinking excessive oil pressure and maybe a faulty turbo.

Still got some petrol left, very tempted....

Opinions greatly appreciated

[Tetsu0san]

Did you run it after you did the head gasket and before you changed the turbo? If you did, was it OK then?

Does it sound rough at the moment too? Sounds like it could be combustion gasses are leaking into the sump which is pressurising it and forcing oil out of any hole it can find. But that wouldn't explain the white smoke. Has the timing belt slipped? Are you losing any water?

[Challo]

Did the head gasket and timing belt last spring and thats been fine til the last week.

Turbo i completed yesterday, its actually burning loads of oil.

When i finished work i noticed there is a big puddle of oil under tail pipe.

Downpipe now covered in oil.

Massive plumes of white/ blue smoke.

Thinking remove turbo, timing case, head and sump n go from there.

Brilliant timing as its below zero here now, no garage to work in...

We must be insane masochists running these things...

All builds character though.

[Ex Member]

If oil is getting to the exhaust, the new turbo is either bad or your timing is massively retarded.

[Challo]

I'm thinking bad new turbo but can't understand the excessive oil pressure.

Oil is leaking from the sump and cyclone breather, where it never did before.

Any ideas?

Suppose I could check the new turbo feed and drain pipes are hollow, though they aren't britpart.

[Ex Member]

Is the crankcase breather plugged?

When you run it with the oil cap off, are you getting a flow of gas outwards? With the breather working and the engine OK, it should be sucking in air.

[Challo]

Will try that and report back.

Thanks for the advice, it's appreciated.

[DaveSIIA]

Is there much radial play on the shaft through the turbo? Check by feel with the inlet hose removed, engine off. If so, new turbo not in the best of health.