smoking problem, how to solve, problem solvers needed! Options

[treydawgs4g63T]

Ok guys, the whole reason i bought the new setup is because my BR580 took a crap and the stock turbo i had on the car was blowing oil into my intake making my car smoke like crazy.

Now the new problem: I got into it a little bit this morning and the bitch still smoked! Im not sure if it is just from the oil left in the intake pipes and exhaust or what the problem is. I thought the problem was the stock turbo i had blowing oil into the intake and it burning up and smoking but im stomped.

Now the weird part, it only does this when you hold the boost for a few thousand RPM's. If I just hit it and then shift quickly it doesnt smoke at all, but if i stay in the gear for a bit it rolls out. Also, the car does not smoke at all at idle.

can you guys give me some ideas as to how i can solve this problem? last time i checked my compression it was 164 across the board.

please and thanks!!!
TJ

[natedogg]

What color is the smoke? If its blue, I'd say its probably just oil left in the intake/exhaust from the other turbo. Sometime it takes a while for that stuff to burn off especially if its synthetic.

If its in your intake you might want to take the time to disassemble and clean the pipes and especially the intercooler because oil inside it can decrease its cooling efficiency.

If its just in the exhaust pipes I wouldn't worry about it too much. Just let it burn off over time.

If the smoke is black, you are running rich, which probably means you just need to adjust your tune for your new turbo.

[treydawgs4g63T]

well i figured it was probably just oil left in the intake pipes and exhaust. The color of the smoke is a darkish grey/light blue which is most likely oil!

I will drive it a little longer and see if it will all burn out and then keep you guys updated.

thanks

[black92_tsi_awd]

My exhaust is still burning a little oil since my turbo blew it's seals.

Did you clean out the exhaust at all? I dropped the downpipe and cleaned it with solvent...but I think the muffler is still coated.

[treydawgs4g63T]

ok guys, im pretty sure i found the problem. Today , i decided to take my intake off and check to see if the 16g had developed any shaft play for warranty reasons! When i pulled the breather tube off the intake snorkel, guess what i found? There was a plastic plug of somekind wedged in their about half way down the hose. I dont know where it came from or how it got there. It is nothing you would find on a car, or even in the engine bay for that matter.

In this , i figured that this was causing no crank case pressure to be able to breathe or escape. Causing it to pump oil through any little passage, in the end burning the crap out of it and smoking. Does this make since to everyone, or am i just thinking way out of this world?

Also, for being a brand new turbo it does in fact have a tad bit of side to side play, but no in and out. Is this normal?

[natedogg]

Sounds like your on the right track removing that breather plug. Some side to side play is completely normal. You just don't want excessive in and out play.

[treydawgs4g63T]

ok guys, now i have a question about how to hook the ex. wastegate vac. lines up! I have them hooked up as follows:

1st. nipple on waste gate= line, t'd into the boost controller and then to the j pipe

2nd nipple on waste gate comes from opposite side of boost controller

now the problem is, when both nipples are hooked up, the car goes to 20+ psi and i cant get it to go down, and the waste gate doesnt open up. When the 2nd nipple is unhooked, it stays at 10 pounds and the waste gate opens up.

what the heck is my problem?

[The Iron Goat]

Sounds like you have the boost controller hooked up backwards, but I don't have a clear idea of how those lines should be ran.

[treydawgs4g63T]

ok guys, i cant figure it out so someone please explain to me how to hook up the vacuum lines to my boost controller and waste gate. Its the Turbosmart ultragate 38mm and it has two fittings on it to hook the lines to. from the intake manifold , where should the lines go? I cant get it to controll it and its running 27+ pounds when i romp it.

[asiankid91]

first u need to get those 650 in!!!!!!

[treydawgs4g63T]

yeah, but i still dont wanna run 27+ psi.......

[black92_tsi_awd]

Does this help HOOKUP

[turbohcar]

Does this help HOOKUP

I've seen that setup before BUT it inhibits the positive manifold pressure signal from reaching the blow off valve as soon as most would like. A better route is to tap a boss into the J-pipe of the turbo as the original setup was designed and route it to the boost controller, then the wastegate actuator.

When you're done it should appear like this:

J-pipe boss/nipple------vaccum hose-----boost controller (ball side)

then from the side port of the boost controller:

Boost controller (side port where the spring is visible)-------vaccum hose-----wastegate actuator



OR for right now just hook the J-pipe directly to the vaccum hose. That will keep it from making any serious amount of boost. How much depends on how much your wastegate spring is meant for and if you're experiencing any creep.

[treydawgs4g63T]

i know how to hook up the stock setup, thanks guys! my question is more aimed at why there is two nipples on the wastegate? thats what has me stumped.

ALso, i was told that i should not be having any boost creep with the external gate.

[natedogg]

While I've never used an external WG myself I'm assuming the two ports reference pressure on either side of the diaphragm that opens the WG. Meaning when you are WOT at full boost you want that full boost signal going to the side that forces the gate open. The other side isn't as critical. You could probably get by just fine letting that side reference atmosphere. Again, this is from someone who doesn't use an external, just thinking through it.

[treydawgs4g63T]

that sounds like a good idea, so ill will try it. thanks

[mitsu90]

go to page 6

[black92_tsi_awd]

Here's the setup for a Tial Diagram