Last week I replaced the rocker gasket in my 2008 animal and also the 8 injector oil seals, cleaned out the intake manifold and made a blanking plate for the egr valve where it joins to the cooler. Took it out for a test drive and all was well for 10 miles then it shit itself. runaway revs, thump and a load of smoke, engine restarted on 2-3 cylinders. a few days later i was going to take a vid to scoot over to a friend and see what he thinks and she started fine, first crank and on all 4 cylinders but with a load of smoke.
Stripped it all back down, Egr pipe was full of oil. I suspected the central rocker cover gaskets were to blame and that was pressurising the rocker and blowing oil into the intakes so I got a new set and buttoned everything back up today. Within
3 miles I have had the same issue, run away revs and after taking the egr pipe off its loaded with oil. Note: when driving before the shit hit the fan she was driving fine, Blue smoke but I was expecting that as there was indeed oil in the cylinders but that clead by the top of the road, within 3/4 of a mile the overrev started and after turning off the key I was hearing a whine for a bit as I freewheeled home then a thud and she was stopped. once i unbolted the egr and the oil ran out she started again fine.
Just stripped out the intercooler praying to find a LOT of oil (from the fist overrun i blame of the rocker intake gaskets) but I didnt find as much as i would have liked, maybe half a cup of oil poured out..... next up was to check the turbo for play and there is none on either side nor it there a load of oil inside it?

Im pretty baffled right now and not keen on putting it back together and 'see' what happens. I was hoping i was going to have a full intercooler from the first problem as I didnt clean it out and that could explain it repeating over again but I cant see how half a cup at the most can cause this???? could it?????

The egr as I said is blanked at the base of the pipe where it bolts to the oil cooler but the electrics are still connected could this be a cause?? I cant see it affecting anything but then I'm not terribly up in diesel engines.

Please help guys I really need to get the truck back on the road but no idea whats causing this.

PS diag computer is showing no faults and previous to this the truck never had any issues bar a head gasket way before I owned her, done 50K since buying it.

Cheers for your time

Jeff

I dont know if this has anything to do with your issue but worth reading anyway ------------> BEWARE ALL NEWSHAPE ENGINE DIY-ERS!!

people dont usually blank off the EGRs on newshapes, there is a gizmo thing that @FoxyChris sells that prevents the EGR valve from opening that he may be able to advise on. I think he sells on ebay and has his own website

I only removed the 4 injector feeds, they attach to the injectors with a brake pipe union style connection, the one mentioned in that link I think is a little lower down from where I was working.

cars sitting stripped down at the min, no heart to put it back together as I haven't a bloody clue whats causing this and don't want to put the engine under any more strain by 'just giving it a go'

I know it's not much help but sometimes you have to step back and have a cuppa and go back to where you started , over the years I've done mechanics I've made mistakes and hade to go back to square one and start over to see if it's something I've fitted or disturbed.
I can't help much as I run the older 4d56 and know nothing about the later ones but more people will be along soon to help out , chin up fella , shouldn't be long before it's sorted

As krutly said it's not normal practice to block off the egr on pram trucks .
There's sensors that pick up the fact that th3 egg is open but nothing flowing through it and can then throw up all sorts of issues .
I've fitted an egr delete module on mine and had no issues .

I wouldn’t recommend just blanking the egr off on a series 4. Whilst you may get lucky and not get an EML on the dash the simple fact is the ecu has no idea you’ve done it and can’t compensate for it. Whether you use one of my modules or not the electronic disabling method is much better.

I have a few leads to investigate, a specialist told me it's quite rare to need to replace the turbo, or so rare he's never actually had to do one without it being a result of something else so I'll button that side of her back up and test some more.
The egr blank didn't bring a light on and the truck seemed fine, could it have been the cause of this ????? I'm my head there shouldn't be that amount of oil vapour flying through the airways that blanking the egr then catches and backs up the system but maybe I'm wrong??? If not where the hell is the oil mist coming from???

May be worth a read thru this thread, the guy who wrote it was a Mitzi tech.
When we did mine i followed this and had no issues.
There are PDF pictures on some of the pages that are a big help.

How to:- De-Coke Manifold & Adjust Tappets (New shape)