matthart

As some of you may have noticed at leaving-time at Ford Fair, my Orion is smoking pretty badly. It's blue smoke.

It started doing it a little while back on overrun after boost, now it seems to smoke heavily not long after the car warms up. Nothing immediately when cold, but about 30 seconds after starting its smoking quite badly. I cant test much more than that as it was pissing the neighbours off ruining their hung out washing!

I just did a warm compression test and got 180 179 175 184 which seems fine to me as the engine has low-low-lower-than-standard-rst pistons. Well within the 10% I understand to be the golden number for compression testing.
The only thing I noticed was when I took the plugs out after warming it up, I got some smoky vapour from cylinder 3 for a few seconds til it burnt off.
Is this compression test fine?
Maybe 3 has some worn valve guide but the smoke coming out seems too much to be just that.

There is a little bit of play side-to-side play in the turbo, and a tiny amount of oily film in the intercooler, but it wasnt new so might be historic.

I am hoping that it's the turbo, but doesn't seem to be the compression side. Can they leak into just the exhaust side?
How can I test this theory?
I'm considering disconnecting the oil pipe to the turbo and jamming the fins somehow and running the car, to take the turbo out of the equation. Good idea?
Anyone want to lend me a known good turbo?

Sorry for the essay but I've been shitting bricks all week thinking I've done the rings in!!

mgtkr1

do you have a good spare turbo you could test? sounds like the turbo to me or poss stem seals. stem seals is a nice easy job if you have an afternoon spare. reality is its a 90m job but bung any holes and take your time. you dont need to be dropping collets into one of the gallerys. have you investigated the breather system? smoke when upto temp usually means oil is bypassing the turbo seal and been burnt off in the ex. however sometimes it could be oil been drawn thru the stem seals on overrun, esp when going down hill or coasting for a few seconds. get the top hat seals via matt lewis. where are you located?

mgtkr1

ps its poss for the leak to be on ex side thus leaking into hot exhaust = smoke when warm. i have a crusty old turbo but its known to work and doesnt smoke. i see your a fair distance away but if your stuck and pay p+p ill can lend it you. i reckon its ex side on the turbo tbh.

darrenb16two

It's the turbo mate, had exactly the same!

matthart

Breather system is brand new and as it's an EFI it vents to air, so don't think it'll be that.
If it's turbo leaking exhaust side I will be a happy lad.

Is there someone on here who rebuilds turbos at a decent price?
Anyone want to stick their neck out and tell me the compression test results are as good as I think they are?

darrenb16two

PM wilky off here mate, builds quality turbos at silly cheap prices. Compression test is good mate

Rob_DOHC

iTrader: (4)

Hi mate

Your compression tests look alright, normally a range within 10% is acceptable. I think there is a chap on here called wilky? who rebuilds them... but you might want to take the opportunity to upgrade at the same time?

Rob,

Rob_DOHC

iTrader: (4)

Lol, great minds and all that Darren!

darrenb16two

matthart

I suppose a cheeky stage 2 wouldn't hurt

mgtkr1

stage 2 is a great improvent over std. also boost's nice and early meaning great point to point response.

matthart

Have sent wilky a PM

I picked up a cossy T3 turbo at FF with ideas of getting that rebuilt, no idea what sizes it is but are these going to more laggy power or more punchy power? I think I'd prefer early boost over top-end.

darrenb16two

Cossie T3's arent that laggy mate. If it has a bolt hole in the front housing beside the intake then its a 4x4 one 55/.48 which is a real nice turbo. Get some pics up so we can help identify it

mgtkr1

i have a .48 60trim and its not nearly as laggy as youd think. and thats with a fmic. if i were you id think about having that (4x4) turbo rebuilt. the way it comes on boost is quite fierce. dont get me wrong the stage 2 is nice and you get better drive at lower engine speeds. the bigger turbo is a good choice if you have some fast flowing roads nearby. if you drive on slower stop start roads id go with the stage 2.

Rob_DOHC

iTrader: (4)

Roughly... a 2wd cosworth t3 is the equivalent of a stage 2, a 4x4 t3 in RS turbo speak is around a stage 3.

I have a stage 2 that I highly rate, its run out of puff at 220ish bhp I still haven't decided which turbo to go for next either.

Rob,

darrenb16two

Do you know much about the gt series turbos rob? Would like to know what there like on a 1600cvh

Rob_DOHC

iTrader: (4)

I haven't driven one with a gt fitted, but im really seriously considering a gt2560r or a gt28..... will have to see

Rogeyboy

iTrader: (2)

Def sounds like a turbo, i tried rebuilding mine and after 3-4months it done this... I used RA Designs in blackpool who stage 3'd .48/.55 my t3 with staggered seals and a 360 bearing for a good price. Im standard comp so im gonna have less lag that you but i get full boost by 3,000-3,300rpm depending on what gear and load im giving the engine. When mine hits, it hits hard and launches the car nicely
TBH i wish i'd specced a less laggy turbo as i love back road blasting and its sometimes abit laggy for firing out of corners etc... So for you i'd def recommend a stage 2!

matthart

Tomorrow morning will take some pictures of the cossie turbo and then once I know which one it is I can go from there.

Also going to fit the OFAM

Off topic (while I've got Rob/Rog here) where do I connect the AFR input on the OFAM?

Rob_DOHC

iTrader: (4)

I'll drop you an email in a min mate

matthart

Right then, ignoring the manifold, what turbo is this?

mgtkr1

.36. could be a stage 2. or std. hard to tell without knowing the seal type and trim size. 55 would indicate stage 2 irc.

matthart

Was sold to me as a cossie turbo, thats all I know and it's not got many markings on it.

On the topic of my smoking CVH, finally noticed there is oil actually leaking from around the turbo where the exhaust housing joins the elbow, so confirmed it's the turbo, so I'm happy, as that is far easier than a ring or something!

Current turbo, nice and oily

mgtkr1

could be a 2wd turbo, as i thin they run a .36 and 55trim. effectively a stage 2.

darrenb16two

Looks 2wd to me mate

Rogeyboy

iTrader: (2)

Thats the oil seal within the turbo gone then...
IIRC pin 22 is the AFR input to the ECU, but if Rob hasn't PM'd or text u then gimme a text and i'll look in my wiring manual for you!

Good luck with it!

matthart

No worries Roger, Rob's told me and it's all wired up, was 0.2 AFR out though, so have used custom settings to massage the numbers a bit til they matched.

And she runs! ....Just!

No more fiddling til I've sorted out this turbo.

mk1trb

havent cosworths got a 3 bolt down pipe fitment and this one has the same as a rs turbo 5 bolt???

wilky

iTrader: (1)

and they .48 exhaust size