Ok, here's the deal. I'm not an expert. I'm here to learn. Thus, I ask questions. So, if the turbo's smoking due to seals leaking, it seems to me that the flow is backing up and causing excess pressure behind the seals, and thus causing oil to get past them.
Now, as I understand it, lighter weight oil will have less pressure and more flow, all else being equal. More flow equals more lubrication and more cooling, according to everything I've gathered from Dr. Haas. All this makes sense to me. So, why would one use a heavier weight oil for a turbo? If all that heat causes the oil to break down, all you do is change the oil more often. You don't use heavier oil to avoid it breaking down, because you defeat the lubrication and cooling effects of the oil.
Regarding exhuast gas temperatures ... I'm not sure they apply directly, because that's not the temperature of the center shaft of the turbine housing, which is not only lubricated with engine oil, but also water cooled. I'd like to know what that temperature might be.
Now, we choose engine oil based on what it does for the engine, not the turbo. What would you prefer to take care of most, the motor or the turbo?
Is there anything wrong with my thinking so far?
Some things are not as they might seem logically. Virtually every high performance car manufacturer with turbocharged engines either recommends synthetic oil or the cars come from the factory with synthetics. Those that don't usually recommend use of synthetics once the break in oil (typically conventional mineral spirits based) is removed at the first oil change.
I'm not trying to argue or persuade. These are just basic facts determined over decades of use in the industry. This is my fourth high performance turbo car -- the others were Saabs and a Volvo. But I'm not an expert either.
I think it is the reasoning of manufacturers, including Mazda in their bulletin to dealers that thinner oils do tend to get past the seals more readily and that synthetic oil is less likely to smoke than conventional oils when it does get past the seals and enters the exhaust stream, hence the recommendation for 5-40 synth if turbo seal leak is an issue. That bulletin was for certain specific VIN numbers and year models as there have been, I believe, at least three changes in our turbo design by Mazda since the car first appeared as an '07 model, and perhaps the latest generation K04's do have better designed seals.
You are right that there is a water jacket in the turbo housing and it helps tremendously. And the center shaft (and therefore the oil going to the journal bearings) does not see the full heat (or at least until it gets fully heat soaked by prolonged WOT), of the exhaust flow. I don't know any realistic way to measure the temps transmitted to the center shaft, but it is going to be much hotter than any NA engine.
There is yet another concern regarding the K04 turbo design in our application and that is that the center shaft is only 5mm in diameter and has been shown in other applications (VW and Audi) to soften if the turbo is operated at much over 5,800 rpm due to excessive heat generated inside the turbo as a result of trying to push more boosted air through the compressor side than the flow rate of the turbo -- it becomes its own heat engine separate and distinct from the exhaust heat on the turbine side.
The VW-Audi K04's were getting hot enough to experience center shaft failure despite water cooling. Here is the report obtained from a Mazdaspeed owner "enganear" obtained from his post on another forum. This is based on research done by Neuspeed, a highly respected aftermarket tuner/vendor for other platforms (not Mazda so far). They were having a rash of K04 turbo failures on the VW-Audi B5 four cylinder turbo engine and commissioned a study of the problem. They suspended their sales of K04's until they were able to determine what was happening.
Report is attached. Center housing excessive heat is a problem for this turbo when pushed beyond 5,800 rpm. Our K04 is a bit different and, as stated above, has been modified several times during the production run. However, to my knowledge the center shaft is still only 5mm in diameter. It needs all the high grade oil we can supply. I do not go so far as to accept Neuspeed's recommendations on oil weights as high as 20w50 in summer. Our
engine requirements may be signficiantly different that VW-Audi and we may need thinner oil for proper flow in some of the very tiny oil orifaces in our cylinder head and camshaft, and to allow proper drainage back into the block for proper lubrication of the crankshaft, etc.
But this illustrates the point that turbocharged engines benefit from use of synthetic oils and we need to be thinking about the effect of heat on the oil in that line returning to the engine from the turbo.
Sorry for the long post. These are just things that cause me to run a bit heavier full synthetic and cause me to stay out of the throttle much past about 5,500 rpm.