Turbo Intake Manifold Leak - Causes?

[Coonass77]

I see a lot of the turbo trucks with oil leaks where the turbo connects to the intake manifold. I'm not a diesel engine or turbo guru by any definition, but this seems to be way more common on these trucks than I would have guessed. What causes it? Is it indicative of a more serious problem than a simple oring/gasket leak? To fix it, does it typically require just new oring/gaskets, or are there other components that fail and cause it?
I realize every truck is different and it could likely be due to a number of different causes, but just looking for some general thoughts/guidance based on past experiences y'all have had. Thanks!

 

[rcamacho]

I’ve seen the same and was wondering as well.


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[Barrman]

I don't know the output size of the turbo. I do know the cross over manifold part has an inside diameter of 2.87 inches. That is such an odd size for a pipe. The single O-ring is very, very thick. I would imagine the turbo output is no more than 2.5 inches. Since the air leaving the turbo could be over 1200° I would guess the O-rings just get brittle with age and shrink some.

 

[Mogman]

Just a small correction, the "air" leaving the turbo is nowhere near 1200 deg. the exhaust side may get that hot but there is quite a bit of isolation between the exhaust and intake side of the turbo including an oil bathed shaft and housing.

 

[REF]

o-ring is P/N 5745167 BUT IMHO that much oil there is a problem, Most likely seal out in the turbo ( if lucky) or engine has a lot of blow by being recirculated by the CDR valve. That much oil in the intake is never a good thing.

 

[Barrman]

I typed before thinking. Thanks for the correction on the temps. I was thinking exhaust side. OOPS.

 

[tomelroy]

I have seen that alot on the inspection pics....anyone actually fix this issue and can tell us what the problem was?

 

[M1028A1ShelterCarrier]

For me it was a bad cartridge seal. Excessive oil in the intake + compression in the crankcase. I pulled the turbo and leak tested it with water. The water freely flowed through the seal to the oil passage. $150 part

 

[HoveringHMMWV]

How time consuming was it to pull the turbo and repair?

 

[M1028A1ShelterCarrier]

A couple hours sitting in the seats, not bad.