Olle_L

Hey all forum members! Its important for you to read the whole post to get the real understanding of the problem.

I have gigantic problems with my fd3s engine. To explain what really happened from the beginning i will tell the whole story. This is the sickest thing iīve ever seen with my cars over the years...

Two years ago i rebuilt my engine with 3mm RA apex seals, solid corner seals, new side seals and so on. I even got it doweled for extra strength, and the rotors, e-shaft and clutch was balanced. I also got it to full BPU at the same time running PFC as engine management.

After that, i got it mapped by a skilld tuner here in Sweden and drove around with full BPU for the whole summer working really good. But in the end of the summer i did some 0-150 km/h pulls and by the last pull the engine started to smoke as hell from the tailpipe (oil smoke, you could really tell it was oil). So i figured it was my turbo (stock secuentials) that went. When i took it of i could feel a axially play, so i bought a new turbo and fitted it, but same thing occured. The car was smoking as hell again...

By this time i figured the new (used) turbo was bad too so i decided to go single. This time i bought a HX40 wich i inspected carefuly and there was no play what so ever. I did all the other mods for the single conversion. After the build i started the car up and it was smoking just as bad as before. I figured it was oil in the exhaust so i took it for a ride to burn of the oil but it didnīt help. By this time im starting to get really annoyed. So i thought it was the turbo again. So i rebuilt the turbo = nothing happened...

By this time i started to think it was the oil control rings. The thing is it smokes all the time. Not just when i start it up like it would if the oil control rings were bad. Anyhow, i pulled the engine and disassembled it with the guy that build it from the start (a very well known rotary engine builder here in scandinavia. He have built race engines for many many years and i trust his skills). To our surprice there was no wrong with the engine what so ever... Apex seals, corner seals, side seals, bearings, rotors, housings etc was in perfect condition. So i cleand all the engine parts very thorough and inspected them at the same time to check there was no cracks and stuff in them. As before, the engine was in mint condition. So i putted it togheter with the help of my engine builder.

Once the engine was in i fired it up and it was smoking like before. So i bought a brand new turbo (third turbo i bought these 2 years) and mounted it but the engine was smoking just like before.

Now i started to check the turbo oil drain thinking it didnīt flow as i should but it did (AN10 return line in to the sump). I have a friend wich has the same turbo and exacly the same oil return line as me and it works perfectly. Next i checked all injectors and they were fine (850 pri and 1680 sec). Same thing = smoky as hell. So i thought maby the oil injectors were stuck open so i blocked them off and premixed 1,5% in the tank with 2-stroke oil to see if there was any change. Now it smokes just as much (maby little litte less) but it smells different. Smells more like a boat engine than before.

This oil smoke makes the car run very bad and it has no idle...

So this is were im at right now. Im starting to loose it as ive checked everything! Dont know what else to do

It smokes so bad you canīt even stand still on the street with it becaus you fill the cupé up instantly.

Could it be the turbo oil return line? Too small?
Could it be something inside the engine?
Have i fitted some vaccum lines wrong?
Have i fitted some other lines wrong maby?
Could it be the brake cylinder?

I seriusly need some help to adress this problem as ive havnīt had it run well in almost two years. Start to think its bad carma or something.

Best regards

Olle Lindén

Herblenny

iTrader: (13)

Sounds like you have tried a lot of things.. At this point I would check and see pre-engine ( check your intake manifold, ic piping etc). Then check post engine to see if oil is going into the turbos or oil coming out of turbos. When you pulled the engine, did you check these areas?

djseven

iTrader: (56)

Can you post a video of it running and the smoke? Problem could be with the rotors where they were cut for 3mm. Sometimes they are cut too deep and it is near impossible to see with the bare eye when inspecting them.

Olle_L

"Sounds like you have tried a lot of things.. At this point I would check and see pre-engine ( check your intake manifold, ic piping etc). Then check post engine to see if oil is going into the turbos or oil coming out of turbos. When you pulled the engine, did you check these areas?"

Thanks for your reply!

When i had my last turbo, the HX40, i could see oil in the intercooler and the piping. There was also oil in the compressor area on the turbo. Now with the brand new turbo there is no oil in those areas. As for oil comming in to the turbo, its coming either from the oil feed line and pushes out through the bearings into the exhausthousing or from the motor itself. Could i have a crack in some of the sideplates och rotorhousings?

BR

Olle Lindén

Olle_L

Thanks for your input djseven!

I will try to get a vid up asap. Allthough its a vid from inside the car in my garage, but you can clearly tell it smokes like crazy.

When the rotors where cut to 3mm it was done by a well known rotary builder and the engine was used on and off track for the whole summer and worked perfectly. But hey, everyone can make mistakes. When i pulled the motor the rotors and apex seals was looked at and they were fine. But as you say, if you canīt see it with your eyes its a possible cause.

You mean that compression could go into the crancase or oil coming out to the combustion area?

BR

Olle Lindén

Herblenny

iTrader: (13)

Maybe feed lines could of been blocked.. If so you should only see oil in do and not pre turbo. Also, was the control rings check carefully?

oo7arkman

iTrader: (2)

The two guys that have posted above are far more knowledgeable than I, but recheck your vac lines as well. Make sure they are set up properly and not pressurizing the crankcase. Specifically, on the oil feed neck. Make sure one of those is going to a catch can or vented properly. If both of those are blocked it will cause pressurization not only causing engine smoking but also roast turbo's due to oil starvation..

Olle_L

It seems i dont really understand what you are saying here (im from Sweden). Do you mean that maby the turbo oil drain is to small? Or do you mean that oil feed is too big? Ive tested the oil return line while the engine was on and it flowed, what i could see, good.

But maby the oil feed is too big for the oil return not being able to evacuate the oil quickly enough?

The oil control rings were checked carefully. Also the oil control ring springs were in mint condition. In fact ALL engine parts were checked carefully... This starts to be a mystery engine!

Olle

Olle_L

I have wired my vac lines as this guy: http://www.negative-camber.org/crispyrx7/gt35rpage3.htm For single turbo setups. Also the crankcase ventilation is wired out under the car (in the front) so there would not be any pressure coming from those. Although there is smoke and pressure coming out of them...

Olle

Herblenny

iTrader: (13)

That's good to hear... at this point, If engine is ruled out, I would check the oil pressure to the turbo and make sure its not too high.

Olle_L

Ok, i should do that. Do you have any ideas on how big inner diameter the oil feed line should be on a slide bearing turbo?

Olle

Olle_L

Here is a little vid i made two weeks ago. Bad for showing the smoke, but you can see in the end off the vid that the whole garage is smogged up. We had to turn the engine off right after the vid and pull the doors open not to "die" in there...

http://www.youtube.com/watch?v=bv-Lwzvpxv0

Herblenny

iTrader: (13)

Sorry, I don't.

I also wanted to make sure, you are positive its oil smoke and not something else.. ie, excessive fuel??? Just wanted to make sure I can't tell from that video nor can i really see and smell your car.

catch-22

iTrader: (2)

Just throwing this out there, was the motor ported past the oil control ring path? Also if the doweling is not done correctly you can have a massive oil leak but i dont think that the oil could make it to the combustion chamber. I would check the rotors like Djseven said. I think Defined Autoworks made a custom tester that pressurizes the rotor so you can see if its leaking in the apex seal slot.

gracer7-rx7

iTrader: (16)

Might want to post your map either here so someone can review it

silverfdturbo6port

iTrader: (26)

looks to me like a death trap. tuning+smoke (rich probably)+ no ventilation or garage door open= DEATH

Olle_L

Thanks for your input!

The motor havn't been ported. As i said in my first post the engine have been running flawless for a whole summer when suddenly it started to smoke after some high loads

Olle_L

Thanks for your input!

The motor havn't been ported. The thing is it was running great for a

The motor havn't been ported. As i said in my first post the engine have been running flawless for a whole summer when suddenly it started to smoke after some high loads

Olle_L

Sorry for my wierd posts erlier, im in the garage right now and im writing from my phone...

the motor havn't been ported. it was running great for a whole summer on and off the track. then suddenly it started smoking alot after som high load pulls. there is no leakage on the outside off the engine. so i don't think its the dowels. and when i took the motor apart it was looking mint. so this smoking thing is wierd...

Olle_L

thank you.
I can promise you its oil smoke. i will try to make another vid today and post it. I've been leaning the fuelmap off as much as i can until the motor almost
stops but there is no difference... Could a malfunctioning vacline to the master brake cylinder cause this problem?

Olle_L

i just measured the oil feed line and its about 6 mm (0,236") in diameter. Is this too big for a slide bearing turbo? And do anyone know what kind of oilpreasure i should have in the motor as standard? Im currently using a AN-10 oil return line.

thanks for all help so far!

Herblenny

iTrader: (13)

Here is my logic... and I could totally be wrong.

If you checked your engine and are sure its not from the engine itself (no oil in exhaust chamber and ports), then only place I could think of oil could burning will be from your turbos. I could see some oil being burn because your oil lines to the turbo having too much pressure... Or your turbo itself is bad because too little oil flow and damaged it?? Either case, if you are confident about engine is not burning oil then it can only be the turbo... hope my logic makes sense or someone please correct me if I'm wrong.. as I might of miss something else too..

CrispyRX7

iTrader: (139)

Excessive crankcase pressure will do this - pinched vacuum line as someone mentioned.

Or don't consider the possibility your engine lunched an oil control ring o-ring.
Like this - I could kill the entire mosquito population in my county if I ran the car for more than 5 minutes. The neighbors loved me!



Regards,
Crispy

Olle_L

This weekend i will be working 32 hours so there will be no time to work on the car. But next monday i will take the exhaust manifold off. If there is oil in both or just one of the exhaustports i will pull the engine out. Its now or never as the summer starts to come close. It is totaly messed up if the engine is bad and i/we didnīt see it the last time i pulld it out...

Thanks for all help and i will keep this thread updated as soon as the weekend is over.

Olle

Olle_L

Ok!

So i took the exhaustmanifold off and this is what the exhaustports looks like:

First three is front rotor and last two i rear rotor