Hey guys, I need your help to narrow it down..here's the story.

I had a problem with the truck as it was intermittently emitting white/gray smoke through the exhaust system. After looking at the spark plugs, I noticed carbon buildup even though the plugs are only 14000 km old. I went ahead and inspect the turbochargers intake system and noticed that both turbo had oil in the intake turbine which is usually mean that the piston rings in the turbochargers are leaking.
I ordered new turbo and proceeded with the replacement as well as replacing spark plugs, engine oil/filter, engine coolant and coolant lines as well as some Jiffy-Tite connectors and turbo coolant hoses on the block as save measure.
Now that all the parts have been replaced, the truck was started and idled for a while in order to confirm the repairs and the absence of leak.
With the new parts installed, the amount of white/gray smoke produced is even worst which render my vehicle unsafe to drive as well as having an excessive amount of oil in the turbocharges intercooler piping even though it was thoroughly cleaned before being reinstalled.

I don't know where to look anymore and leaning towards having bad engine internals.
I emailed my ford dealership to book an appointment for them to look at it because I'm not equipped for "advance" diagnostic nor do I have a proper shop to do so.

What do you guys think?...bad piston rings ?

Thanks

 

Trace the turbos back to the source until you find the point without oil.

If you're saying the intercooler was definitely all cleaned out prior to reassembly, then it's coming from somewhere upstream - have you checked PSV valves?

 

Thanks for the reply,
I restored the PCV system back to stock thinking the Mishimoto catch can had a deflective check valve but unfortunately the problem persist. I was doing some hardcore reading last night and in some cases, having a blown head gasket between the combustion chamber and an oil passage could pressurize the crankcase enough to create the problem I'm having. I'm not equipped to test that but a leakdown test should confirm the issue.
The truck is now gone to Ford. I will keep you updated !

 

I had similar symptoms on my 2013 caused by a stuck check valve on a catch can config. Dealer replaced the intercooler and cleaned things up and it was fine after that. No more catch cans for this guy!

 

So you didn't trace where the oil was entering the intake tract then?

Hopefully Ford will be able to do so, please let us know.

 

No I didn't but the upstream (TB) intake was dry and only the bottom was wet (intercooler and piping). When I pulled the old turbos, both the intake side were wet and the exhaust side were full of soot due to the burning oil.

I'm nervous to hear the diagnostic !

 

I wouldn't be surprised if they tried to tell you it's the turbos.


From what you're saying, you're getting blowby oil from the PCV system, correct?

 

That's funny you said that, I just got a callback and they're saying it's the left turbo even tho it's brand new (not remanufactured).
I'm following the same diagnostic chart as the tech does and in case of an excessive oil consumption/lots of grey/blue/white smoke the first thing to look at are the turbos. I called back and asked for a leakdown test as well as a compression test just to be sure.
The chances that a brand new turbo is defective right out the box is extremely slim which is why I don't believe the technician right now.

 

Here's a quick update !
The dealership performed a compression test as requested and the result were fairly even all across with a compression of 123/124 psi. They called back and said it would be a waste of money to do the leakdown test so I asked them to put it back together and I towed it back home.
I was able to borrow a pressure differential tester from work and I just finished the test. Every cylinder had less then 4% leak which is very good so I can confidently say that the engine is in great shape.
I also tested the PCV system for leaks and over pressure and the tests were negative.

I think the problem is that I received a defective brand new turbo...I'd say there's less than 1% chance but it's not impossible.

If there a test I should do that I didn't do already ? Would you recommended something else ?

 

Well humph. That's good news i guess - and sorry i can't help further, turbos are something i know the theory of and yet have never had one myself or worked on one. And yes, many people don't always get that whilst low %, you absolutely can get faulty new parts, which sucks