Never Ending Long Term Smoking Issue

[DAT335]

Bit of info first on my car. Have 2006 335i N54 coupe. I have had the engine built with forge internals. Running Pure Stage 2 twins with Fuelit PI system, Fuelit stage 2 lpfp, the head has been serviced and tested. Valve stems have been replaced and valve cover and PCV system is all new. Running catch can on Highside from BMS. Have tft inlets and running 7.5 step intercooler. Tial bov and BMS charge pipe. Upgraded fuel lines with regulator. Standard gearbox, AR catless downpipes and remus exhaust. HPFP was replaced 3000km ago with a genuine one and the spark plugs are 2 step colder which are brand new. Injectors are all index 12s.

Heres my issue. I have had a few mechanics try to sort this smoking and oil consumption and fuel in the oil but no one can sort it out. First everyone says its the PCV or valve cover but they are brand new. Then the say its turbo seals but i highly doubt cause the turbos have been replaced and have about 2000km done on them without any high boost at all as the car sat in the garage for a few years plus there is now oil in the downpipes at all. Then the mechanics say its injectors which could be it but I replace all the primary bank but still smokes and consumes oil. The port inject has been disconnected completely to make sure it isn't the issue. The valve cover gasket is brand new aswell.

Did a compression test and came back around the 160 mark in all cylinders. The proceeded with a leakdown test which all came back at 95 psi on all cylinders.
Saw that cylinder 2 new spark plug was wet and starting to fowl so changed the injector 2 and 1 around as injector 1 was brand new but the issue stayed in cylinder 2. Have sent the oil away to get tested but won't get the report till late this week.

This is what the recent mechanic performed:

CARRIED OUT OIL CHANGE WITH CUSTOMER SUPPLIED CASTROL 10W-60 ENGINE OIL
REPLACED ENGINE OIL FILTER WITH OUR SUPPLIED MAHLE FILTER.


PREVIOUSLY FOUND ENGINE TO BE MISFIRING UNDER LOAD.
ROAD TESTED VEHICLE AND FOUND ALL CYLINDERS TO BE COMPENSATING FOR A PRIMARY MISFIRE ON CYLINDERS 1 & 6
REMOVED ALL SPARK PLUGS FOR INSPECTION AND FOUND A COMBINATION OF LEAN, RICH AND OIL DEPOSITS ON ALL SPARK PLUGS. ( IMAGE PROVIDED)
CARRIED OUT COMPRESSION TEST ACROSS ENGINE AND FOUND:
- CYL 1 ~ 160PSI
- CYL 2 ~ 175PSI
- CYL 3 ~ 170PSI
- CYL 4 ~ 165PSI
- CYL 5 ~ 160PSI
- CYL 6 ~ 170PSI

ALL PRESSURES ARE WITHIN A 10% TOLERANCE OF EACHOTHER. COMPRESSIONS O.K
REPLACED SPARK PLUGS WITH CUSTOMER SUPPLIED 2 STEP COLDER PLUGS.
GAPPED TO 0.018"
RE INSTALLED IGNITION COILS AND ROAD TESTED VEHICLE. NO MISFIRE APPARENT, VEHICLE STILL SMOKING.
REMOVED CYLINDERS 1&2 SPARK PLUGS - FOUND CYLINDER 2 SPARK PLUG TO BE HEAVILY FOULED.
CLEANED SPARK PLUGS AND MIGRATED CYLINDER 2 INJECTOR TO CYLINDER 1 FOR TESTING
CARRIED OUT CODING MIGRATING OF INJECTORS.
CARRIED OUT ROAD TEST OF VEHICLE AND RE INSPECTED CYLINDERS 1 AND 2 PLUGS
CYLINDER 1 STILL CLEAN AND 2 STILL FOULED, SEEMINGLY WITH ENGINE OIL.

REMOVED ALL IGNITION COILS AND SPARK PLUGS
CARRIED OUT FULL CYLINDER LEAK DOWN TEST AND FOUND:
- CYL 1 ~ 10%
- CYL 2 ~ 8%
- CYL 3 ~ 12%
- CYL 4 ~ 10%
- CYL 5 ~ 13%
- CYL 6 ~ 8%

LEAK DOWN TEST PASSED ACROSS ALL CYLINDERS.
INSPECTED PISTON HEADS USING BORE SCOPE AND FOUND CYLINDERS 2,3,4 AND 6 TO BE WET AND OILY.
INSPECTED BLOCK BORES WITH SCOPE, FOUND CROSS HATCHING INTACT.
RE CLEANED PLUGS AND INSTALLED WITH IGNITION COILS.

REMOVED CUSTOMERS CATBACK EXHAUST SYSTEM, SOAKED MUFFLERS IN DEGREASER AND CLEANED TO ELIMINATE OIL.
CARRIED OUT FULL COOLING SYSTEM FLUSH USING 4.0 LITRES OF BMW APPROVED BLUE COOLANT CONCENTRATE.


Sort of at a cross road as it just keeps costing a fortune trying to sort this issue out. Would love to hear anyones feedback.

 

[BEAT_ITN54]

How is the crankcase vacuum during idle? If no vacuum is present you will definitely smoke

 

[DAT335]

How is the crankcase vacuum during idle? If no vacuum is present you will definitely smoke

I will double check. pretty sure its sucking though.

 

[537sk]

I will double check. pretty sure its sucking though.

I have the same issue. Engine rebuilt and new pure stage 2 ate the same time. I did the brake in period break in oil etc. compression and LDT are good.
I can see there is major shaft play on the turbos but not oil sign on the hot side impellers.

On your side do you have any news? did you find something?

 

[KnighTT]

On the high side catch can, did you put a check valve in or retain the stock flapper valve?