How to add + 60HP safely/reliably?

[SSage]

Looks like leaking turbo to me, where else could it be from? That looks mighty oily, not safe IMO. I would park it till the intake was oil free. As far as tuning the stock Smarty tunes they have out these days don't smoke much at all. My 03 runs clean on SW5, all stock.

 

[tjm]

Did they have any insight on where the oil is coming from?

They concurred with the video i posted above that shows where a turbo can leak Coasty

 

[tjm]

Intercooler cleaning instructions from the manual below

I double checked the drain tube, removed it and ran a fat screw driver down into the oil pan while reaming the orifice. There are no obstructions from drain to the bottom of the oil pan!

That leaves excessive crankcase pressure or the turbo.

Turbo:
They took the turbo apart, no signs of wear, no wobble, and put it back together for free.

Crank case pressure:
Oil PSI is 40 by the dash gauge. Breather is breathing. Engine idles like she always has. Are there any other signs of momentary excessive crankcase pressure? Seems like the probability of that is very low.

This all started out as a exhaust manifold replacement that turned into something else when I sheared off the turbo manifold bolts and had the turbo rebuilt with a new housing.

The turbo is the only thing that has changed that is close to oil.

After I clean everything up I'll see if shes still spitting oil.

 

[tjm]

Cleaned everything up and went for a spin. saw 32 PSI on boost a couple of times. Turbo is still spitting oil.

At idle the oil fill cap, when resting over the oil fill is not dancing around. I dont think I have excessive crank case pressure.

 

[Ozymandias]

Drive over to that Turbo place and show them how that can be right!

Edit: Your Turbo was working fine before they "rebuilt" it, so this is blabla talk about oil return and crankcase pressure and all that. It worked fine.

 

[tjm]

I'm going to do that Thursday Ozy. I went to home depot to get a mini-excavator for a honey-do-list project. Going to knock that out tomorrow. I'll let them observe the normal crank case vent. Then ask them how a turbo can sling oil if the drain is fine and crank case pressure is normal. They're supposed to be the experts.

 

[tjm]

Well, one day on the excavator turned into 2. Didn't make it to the turbo shop before Christmas eve. So in my down time I opened an account on the cummins service portal where i found a TSB on turbo oil leaking, and bought a holset repair manual. From the holset manual it expliclty states that the drain tube cannot have any bends in it that are less than 30 degrees from horizontal.

enter my drain pic. Does that look like < 30 degrees? I removed it and sure enough it was. So i straightened out the bends and compressed it by hand. From the turbo drain to the oil pan is only about 8". So i made it shorter than needed and stretched it up to the turbo drain.

Here's the new drain orientation. Voila! no more turbo spitting oil.

Here is the TSB - had to do screenshots as they wouldn't let me download anything but a web

page.

Here is the Holset repair manual(s)