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 Old 07-24-2011, 04:39 PM   #1
 
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Default Blown Turbo

I just wanted to give you guys another data point on this issue and perhaps get some advice.

I just got my car back from the dealer. I stocked out beforehand (except for the fuel pump – I just removed the sticker) and fortunately I didn't pay a dime to have my turbo replaced. The mods I was running:

Cobb intake, Cobb DP, CPE Fuel Pump, CPE RMM, AP with stage2 tune, 1 step colder plugs.

The first indication that there was a problem was quite obvious. After about 4 hard pulls in a row, as soon as I stopped at a stoplight, my exhaust started shooting out clouds of white smoke. Not just a little – it was billowing out. KiddMnky was right beside me so we turned into a parking lot to take a look. There appeared to be some smoke leaking out past the exhaust manifold, since we could see a bit of smoke coming out around the heat shield.

I limped the car home and started trying to troubleshoot. I bought new exhaust manifold bolts and gasket and made sure no exhaust leaks were occurring. I also installed a bnoon bolt. At first, the bnoon bolt seemed to cure the smoke, but after a few WOTs, the smoke was back nearly as bad as before. Not only that, but at this point I started hearing a suspicious sound when accelerating that sounded like a bearing being tortured. I also noticed that boost was not getting anywhere close to targets (12 PSI in 2nd gear, for instance)

At this point I gave up, stocked out, and took it to the dealer.

Now the question is:

Is installing a downpipe on these cars playing with fire? Or did I screw up the install somehow that led to this problem? I'm guessing the stock turbo doesn't like the reduced back pressure, but even more so if there is an exhaust leak.

The way I see it, I have 4 options:

1. Leave the car stock, sell my parts.
2. Go back to intake, tune and leave the exhaust stock.
3. Get the turbo reworked, or big turbo.
4. Sell my car and get something else that won't blow up the turbo with exhaust mods (if such a thing exists).

Any thoughts or suggestions would be massively appreciated...
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 Old 07-24-2011, 04:55 PM   #2
 
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I say keep the car and enjoy it. It's your call when it comes to throwing all the parts back on or not, if it was me, i'd go back to stage 2. It's a car and shit happens, even new cars have things break. And regardless of if you sell the car and switch to something else, you're going to find out that it will also have problems and known issues all it's own. Just my 2cents.
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 Old 07-24-2011, 04:58 PM   #3
 
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keep mods. keep car. drop k04. pick up 3071 and have some fun blowing money like the rest of us.
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 Old 07-24-2011, 05:02 PM   #4
 
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My story is very similar. I blew my turbo with SRI/TIP, race pipe, KMD internals, catback exhaust, 1 step colder plugs, RMM, stage 2 tune. I had initial smoking after I got fuel cut during a 1st gear launch. Month later, I had shaft play, stocked out (except RMM, internals, and catback exhaust), and took it to the dealer.

Now I'm running the new turbo with everything I had on before except the race pipe. I've been trying to get my tune down before I go Stage 2 again. The car works perfectly fine, if that's what you're worried about. As for your choices, it really depends on what your plans are with the car and how much disposable income you have.

Good luck.
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 Old 07-24-2011, 05:10 PM   #5
 
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I'm really kidding myself that I will keep this car (or my next one) stock. How boring is that?

One thing I know I am doing for sure is getting a daily driver. I can't afford to be screwing with my car and possibly leave myself without transportation to get to work. This time around I borrowed a car from a family member and had it for an entire month while I was troubleshooting and then waiting for the dealership to fix it, but I can't always count on that, nor do I want to.

At the risk of committing a grave act of blasphemy, I have been looking into STis recently. But I'm having trouble justifying the extra 12k or more to get one.
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 Old 07-24-2011, 05:53 PM   #6
 
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This is the 2nd blown gen2 turbo thread in one day. Not good...looks like we're in for the same issues as gen1's.

Good side is 3071 may come sooner than I expected
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 Old 07-24-2011, 06:02 PM   #7
 
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I'm a little weary of going big turbo, but its not out of the question. I basically shed my newb card doing the downpipe install (and uninstall), although I had some help. The big turbo installs I've heard about so far sound pretty horrible.
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 Old 07-24-2011, 06:06 PM   #8
 
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^ STI? Ringlands busting will be your new nightmare-in-waiting.
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 Old 07-24-2011, 06:07 PM   #9
 
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i blew my turbo on a stock car with 4.5k on it this past monday. had the turbo and gasktes replaced under warrenty thank god. had all the same symptoms as you.
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 Old 07-24-2011, 06:10 PM   #10
 
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Wow a whole 2 today....Look any product anyone makes are going to have a percentage fail. A good comparison would be your friend john (kid) he has put his ko4 @ 22psi for how long now and last time I talked to him it was fine. To bad you werent logging maybe be you spiked to some high ass number with the ots tune.
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 Old 07-24-2011, 06:17 PM   #11
 
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this car is fun, so you should keep it.

shit is bound to happen.

if you sell it, i call dibbs on ur DP
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 Old 07-24-2011, 06:46 PM   #12
 
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I guess it's possible I was boost spiking or something...but every time I went WOT when I was monitoring boost it was too low if anything. At the time I was more concerned about knock, which was better at stage 2 than stage 1 actually.

I may end up selling this DP even if I do keep the car. I'll keep you in mind.
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 Old 07-24-2011, 06:49 PM   #13
 
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Originally Posted by JD80 View Post
I guess it's possible I was boost spiking or something...but every time I went WOT when I was monitoring boost it was too low if anything. At the time I was more concerned about knock, which was better at stage 2 than stage 1 actually.

I may end up selling this DP even if I do keep the car. I'll keep you in mind.
Moral of the story is...Get a perm tune (DJ) or your turbo will blow
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 Old 07-24-2011, 07:07 PM   #14
 
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Originally Posted by JD80 View Post
2. Go back to intake, tune and leave the exhaust stock.
Do #2!! LOL
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 Old 07-24-2011, 08:17 PM   #15
 
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Just get a big turbo and get rid of the ko4. The turbo by nature is pure fail. It's working to had to make the power.
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 Old 07-25-2011, 06:21 PM   #16
 
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Originally Posted by JD80 View Post
I'm really kidding myself that I will keep this car (or my next one) stock. How boring is that?

One thing I know I am doing for sure is getting a daily driver. I can't afford to be screwing with my car and possibly leave myself without transportation to get to work. This time around I borrowed a car from a family member and had it for an entire month while I was troubleshooting and then waiting for the dealership to fix it, but I can't always count on that, nor do I want to.

At the risk of committing a grave act of blasphemy, I have been looking into STis recently. But I'm having trouble justifying the extra 12k or more to get one.
I just had the same thing happen and felt the same way, thinking about trading this car in after the repair, but it's a lot of fun to drive, thats why I bought it over other cars in the first place.
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 Old 07-25-2011, 06:24 PM   #17
 
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wow, gen2's are blowing turbos like no tomorrow.


GenWON > genPU
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 Old 07-25-2011, 09:23 PM   #18
 
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Originally Posted by CobraStarVIII View Post
I just had the same thing happen and felt the same way, thinking about trading this car in after the repair, but it's a lot of fun to drive, thats why I bought it over other cars in the first place.
Any mods when you blew it up?
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 Old 07-26-2011, 11:18 AM   #19
 
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I found this... interesting read on the K04

K04 TURBO REPORT FROM NEUSPEED
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 Old 07-26-2011, 11:39 AM   #20
 
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K04 users should always bring their vehicle to a complete stop and allow the engine to idle prior to shutting down the engine. Recommended idle times vary from 1 minute after mild driving, to 5 minutes after aggressive driving. The idle-down procedure circulates fresh oil and coolant through the turbocharger, allowing it to cool gradually, prior to shut-down.
That's interesting...5 minutes seems like a lot. Definitely not 30 seconds as recommended
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 Old 07-26-2011, 01:25 PM   #21
 
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Did you see the viscosity of recommended oil? 20W50 in summer, 10W40 in winter.

I can believe 5 mins for aggressive driving and with a ton of boost, but 1 min after mild driving? The turbo must be spinning even during mild driving?
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 Old 07-26-2011, 01:43 PM   #22
 
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Yea that viscosity issue is a little to general. Winter in North Dakota is a lot different than winter here in Florida.

I leave it on for 30 seconds. I don't usually full-boost to my parking lot anyway. I'm usually stuck at a red light after going WOT.
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 Old 07-26-2011, 02:06 PM   #23
 
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@ least is the turbo and not the motor?
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 Old 07-27-2011, 09:23 PM   #24
 
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I'm next GD it!!! 3 good runs from 3k-6k and HUGE smoke out the rear. Warranty replaced but a huge hassle. WTF!!! Trying to figure it all out.........No mods other than AP Stg 1 93.

BTW - Christian says it's the PCV system like Gen 1 not the K04. Nice Mazda!

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