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 Old 01-05-2018, 07:15 AM   #1
 
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Default Troubleshooting Smoke

So, last week I suspected my stock K04 blew and I was pouring smoke from my exhaust. When I pulled it, it had about a pretty sizeable pool of oil inside the compressor and the shaft had lots of play, so I ordered a BNR S4, did the swap, and retuned.

When I started it back up it was still pouring smoke, but thatís to be expected because there is likely still oil in the downpipe. I was told to let it idle for a while and drive it for a while. The smoke subsided, but never fully went away. I was told it would take a while to burn all of it off. I was out of town and thought everything was OK, so I drove it about 300 miles back home. I didnít drive it at all yesterday.

Today, I started it up and the smoke was awful. My car was literally a rolling fog machine and it smelled so bad ó like burned clutch mixed with burned plastic coming from the exhaust. I pulled over into a meineke parking lot and the mechanic there immediately said anytime he sees someone smoking that bad itís usually a blown head gasket. I told him about my recent turbo swap and he said itís possible thereís coolant leaking internally in the new turbo. I checked the coolant level and sure enough the reservoir was almost empty. The coolant also appeared dirty. Itís brand new coolant, replaced with the turbo.

Any ideas out there?
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 Old 01-05-2018, 07:20 AM   #2
 
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Do a leakdown test.
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 Old 01-05-2018, 01:57 PM   #3
 
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I don’t have a compressor to do a leak down test, but I did do a compression test:

Cyl 1: 152psi
Cyl 2: 151psi
Cyl 3: 151psi
Cyl 4: 152psi

So, it seems the cylinders are fine... Still checking things out.
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 Old 01-06-2018, 12:55 PM   #4
 
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What color was the smoke

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 Old 01-06-2018, 01:30 PM   #5
 
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It’s a dirty white, kind of brownish tinge. But it’s thick. It seems to only be bad after the car sits for a while or if I let it idle. My coolant was a bit low (still hadn’t been fully burped after a coolant flush), and simply topping off the coolant and driving it a bit seems to have made the smoke greatly subside. Going to take her back out today and see if it’s any better.
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 Old 01-07-2018, 09:44 AM   #6
 
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Went out to car this morning and checked fluid levels. Coolant is fine, oil was totally off the dipstick. Apparently the smell is burning Rotella T6. Oil is dumping into the exhaust. I’m losing my mind here.
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 Old 01-07-2018, 09:51 AM   #7
 
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Pull your plugs see if piston top is wet. I had great compression, took the engine apart 3 out of 4 ringlands broken.

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 Old 01-07-2018, 10:21 AM   #8
 
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Good luck
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 Old 01-07-2018, 10:58 AM   #9
 
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1, 2, & 4 are bone dry. The top of the piston in 3 is wet.


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 Old 01-07-2018, 11:25 AM   #10
 
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How new is the valve cover gasket? I know you said you didnt have a compressor but it might be time for a leak down test.

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Originally Posted by Solarsurge View Post
1, 2, & 4 are bone dry. The top of the piston in 3 is wet.


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Does it still pull pretty well when you drive it hard?

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 Old 01-07-2018, 11:33 AM   #11
 
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Stock valve cover gasket. Thereís also a noticeable amount of oil seeping out around the VVT solenoid. Thatís new.


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Originally Posted by tmillner View Post

Does it still pull pretty well when you drive it hard?

I really didnít push it because itís obvious thereís something wrong. I did open it up a bit when the smoke subsided and it drives perfectly fine. Itís just a rolling fog machine.

Side note: Cylinder 3 has a VERY strong odor of what Iíve been smelling out my exhaust, so itís likely at least part of the problem.




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 Old 01-07-2018, 11:39 AM   #12
 
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Originally Posted by Solarsurge View Post
Stock valve cover gasket. Thereís also a noticeable amount of oil seeping out around the VVT solenoid. Thatís new.


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I really didnít push it because itís obvious thereís something wrong. I did open it up a bit when the smoke subsided and it drives perfectly fine. Itís just a rolling fog machine.

Side note: Cylinder 3 has a VERY strong odor of what Iíve been smelling out my exhaust, so itís likely at least part of the problem.




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Do you have an occ?

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 Old 01-07-2018, 11:41 AM   #13
 
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Yes


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 Old 01-07-2018, 11:43 AM   #14
 
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Any chance you can post video of it smoking?

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 Old 01-07-2018, 12:17 PM   #15
 
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Itís low on oil, so I donít want to start it up. However, this lovely photo is what is coming out of my tailpipe. IMG_0194.JPG


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 Old 01-11-2018, 09:26 AM   #16
 
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Took it to a shop and the mechanic did a full diagnostic on everything. The leak down test was fine. It was 20% across the board while cold. He said itís definitely bad seals in the compressor. Looks like Iíll be pursuing a warranty replacement on the brand new BNR S4.


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 Old 01-11-2018, 09:27 AM   #17
 
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That's actually good

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 Old 01-11-2018, 09:29 AM   #18
 
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I take care of my baby. I was gonna be pissed if I broke her at only 90k. You have no idea how relieved I am.


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 Old 01-13-2018, 08:20 PM   #19
 
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So, in a interesting turn of events, I now know exactly what happened. It was basically a chain of events and just bad luck set in motion by the original turbo blowing:

1. Coolant and oil mixed as a result of the original blown turbo.
2. The water in the coolant vaporized and was ďcollectedĒ by my oil catch can extremely rapidly due to cold.
3. Due to the arctic temperatures we had, the catch can literally froze into a block of ice.
4. Catch can feed hose got clogged and crank case pressurized.
5. Excess pressure in the crank case pushed up the oil return line from the new turbo, preventing it from draining oil properly.
6. Unable to drain, the turbo just dumped the oil down the exhaust.

Itís been driven fairly hard and temps dropped again tonight. No smoke, no oil loss.

As for the S4, it seems to not be an issue with the new turbo at all. Bryan at BNR Supercars deserves all the credit for immediately knowing it was a crank case ventilation issue where 3 mechanics told me I either had a bad engine or a bad turbo. That dude knows his turbos.


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 Old 01-13-2018, 08:28 PM   #20
 
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How the hell did he figure that out?

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 Old 01-13-2018, 08:32 PM   #21
 
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He was very adamant about the quality of his turbo. He was like ďI HIGHLY doubt itís the turbo,Ē and he told me right away it sounds like itís a crank case pressure issue. I figured out the rest on my own lol


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 Old 01-13-2018, 08:35 PM   #22
 
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Man that's awesome. I'm burning oil as well can't tell where from. I have a bnrs4 so I have some figuring to do

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 Old 01-13-2018, 08:36 PM   #23
 
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Check that crank case pressure


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 Old 01-13-2018, 08:37 PM   #24
 
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Blew my dipstick out twice already so Im leaning that way

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 Old 01-13-2018, 08:39 PM   #25
 
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Yeah if you blew out your dipstick that is 100% your issue. I am running the Corksport OCC set up as in this photo. The red X is the back port of the IM capped off.



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 Old 01-13-2018, 08:42 PM   #26
 
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Interesting, how much boost are you running? Didn't want to go with one from pcv to manifold and one between valve cover and intake?

I'm thinking about getting the oil cap breather instead of another can. I might try your method

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 Old 01-13-2018, 08:49 PM   #27
 
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I have to drain the can often due to condensed moisture, so itís definitely doing something.


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Originally Posted by tmillner View Post
Interesting, how much boost are you running? Didn't want to go with one from pcv to manifold and one between valve cover and intake?

Right now Iím only on a base map, as I just put the S4 in last week. So itís just running wastegate spring pressure. Iím hitting around 18psi. Dual catch cans are a bit excessive unless youíre pushing some serious power.



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 Old 01-13-2018, 08:52 PM   #28
 
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Not true, recommended over 24psi, I'm hitting 30 occasionally

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 Old 01-13-2018, 08:54 PM   #29
 
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Donít forget I was running a K04 last week. Dual catch cans with a K04 is just a waste of money lol


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 Old 01-13-2018, 08:55 PM   #30
 
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Get ready for some fun, you guys have e85 close by dont you?

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 Old 01-13-2018, 08:56 PM   #31
 
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Iíve got a Snow water/meth kit. Iím not messing with E85 lol


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 Old 01-13-2018, 08:57 PM   #32
 
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Originally Posted by Solarsurge View Post
Iíve got a Snow water/meth kit. Iím not messing with E85 lol


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I'm running both, e85 is the way to go if you can get it

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 Old 01-13-2018, 08:59 PM   #33
 
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Let me get the darn thing stable first


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