PCV Troubles (Drowning in Oil)

[_mpreza]

Any sugestions on what may have caused this or even a fix would be great!

Heres the lowdown...
Car hasnt missed a beat FBO last 6 months hauling ass on 100% e85, PS2s, etc... etc...

From day one ive been using the BMS OCC with the RB External PCV Setup (Mishimoto OCC)

I decided after 6 months to take full advantage of the RB kit and tap/plug the cyl head, at the same time i thought might as well get rid of secondary cats.

Turned the car on, and normal e85 cold start steam/smoke.......
And i noticed after about 5min something wasnt right.
Ahh well probably junk from the welding in the exhaust i thought, car still ideling as per normal.
So after it got up to temp, went for a drive........... Smoke smoke smoke smoke smoke and more smoke. And consuming more oil than fuel lol. No oil leaks as such.Havnt lost a drop of coolant.

Aside from the exesive smoke and oil consumption and miss fire on cyl 2(Shown in pics) it appears to run fine.........

Im all ears, what do you guys think?

 

[Velocity26]

I assume that you pulled off the intake manifold and sealed the bottom to make sure that no metal shavings (from the tapping) got into the cylinders, by way of the intake ports? If not ....

 

[_mpreza]

Yes, i followed the detailed DIY regaring the tapping procedure... its really got me stumped.

 

[bradsm87]

Give us a run-down of your exact PCV system and piping route.

 

[Erichale77]

I have the same thing done to my motor and as soon as i removed secondary cats my car started smoking as well. I ended up having a vacuum pump installed into crankcase. Smoking was not caused by turbos, oil lines, plugged head or anything else as replaced EVERYTHING including new motor. I always suspected by removing cats there was maybe a lack of adequate back pressure but i couldn't prove this.

 

[_mpreza]

Pictures would definatly explain it better than text, hope this helps.
I did pull out/apart the toyota pcv valve and gave it a good clean.
(Degreser, Comp Air,Soap,Water,Comp Air and Lubed O-rings with fresh oil)
I should probably mention ive also replaced the VC & VCG with no such luck.

 

[_mpreza]

Your joking!! So you had oil pooling in your intake valves like mine?
How many km on your engine when this occured?
Im wondering if i should unscrew the grub screws and see what eventuates...
Im guesing ive got a heap of oil in my mufflers now, and thats gunna smoke for weeks till its all burned out
You wouldnt happen to have a pic of your setup?

I have the same thing done to my motor and as soon as i removed secondary cats my car started smoking as well. I ended up having a vacuum pump installed into crankcase. Smoking was not caused by turbos, oil lines, plugged head or anything else as replaced EVERYTHING including new motor. I always suspected by removing cats there was maybe a lack of adequate back pressure but i couldn't prove this.

 

[Velocity26]

Are you catching a lot of oil in the catch cans?

I find it very coincidental that your valve guide seals would suddenly go bad at the same time that you did this procedure. Unless you somehow nicked an oil passage when tapping for the plugs, I can't figure out how you could get enough oil to pool in the intake valves any other way. If you have an overfilled a catch can, the oil could be getting sucked back into the intake through the throttle body vacuum line, or it could be pouring into the rear turbo inlet tube where it would end up in the charge pipe after traveling through the intercooler. I would guess the intercooler would have plenty oil in it, if this is the case.

 

[_mpreza]

Catch cans are getting oil in them yes, wouldn't say excessive.
But definitely a little more since plugging the ports.
Im confident either of the cans have gotten full to the point there sucking in oil,
Ive been constantly checking both of them.
And yes, your spot on with my intercooler holding some oil too.
How close are these oil pasages if i nicked them,
would it be safe to say if i did nick any oil passages it would have only been cyl 2?
As all other spark plugs look perfect, cyl 1,3,4,5,6 intake ports dont look anything like cyl 2.
Besides the bushfires from the exhaust, on idle it will occasionally throw a cly 2 missfire code.

Ive taken the VC of and cleaned...

IC
CP
VC
2 x OCCs and hoses associated
Flapper Valve (New)
PVC Valve
CP & Inlet Manifold Sensors
Inlet Manifold

As that started drying, i started unscrewing the grub screws
that at the time i coated in a "fair" amount of blue locktite.....
I managed to get one grub screw out of the 6 and the other 5...
Well they're "fairly" rounded.
Ill give it another go tomorrow.

Attached are a few more pics that may help......

 

[Velocity26]

I don't know how close you could be to an oil passage, I am just "grasping for straws" so to speak. I am trying to come up with something reasonable that could explain why you suddenly have a lot more oil getting into the cylinder after tapping some passages and installing some plugs. If anything, plugging the ports should allow a lot LESS oil to get into the cylinders.

When I installed my catch cans, my smoke practically disappeared. One can has to be drained regularly, or it will overfill.
One afternoon the smoking suddenly came back with a vengeance, I pulled up to a traffic light and the car created a huge cloud of smoke and I thought I had blown an oil line. First thing I checked was the catch can, it was full to the point that oil was being sucked into the intake from the catch can. Drained the catch can and the smoke went away. I wish your problem were as simple to fix.

 

[Torgus]

As I have driven my car about 50 miles since I installed the dual catch can w/ plugged head how often are you emptying out the cans? Like 2k miles? 4k? Just curious what interval I should be expecting.

 

[Velocity26]

The catch can that is attached to the PCV and throttle body can not go past 2k miles or it is very full. The catch can on the Flapper side never seems to collect any more than a mist. It is always "wet" with oil, but there is never enough for me to pour out.

FWIW, my catch can is on the driver's side, on the support brace, and the oil is collects is uncontaminated oil. Some people report that the oil they collect is milky with moisture contamination but mine looks just like the oil in the engine. I could pour mine back into the crank case, although I never do that.

 

[Torgus]

The catch can that is attached to the PCV and throttle body can not go past 2k miles or it is very full. The catch can on the Flapper side never seems to collect any more than a mist. It is always "wet" with oil, but there is never enough for me to pour out.

FWIW, my catch can is on the driver's side, on the support brace, and the oil is collects is uncontaminated oil. Some people report that the oil they collect is milky with moisture contamination but mine looks just like the oil in the engine. I could pour mine back into the crank case, although I never do that.

Good to know thanks!

 

[fmonteiro444]

I have the same thing done to my motor and as soon as i removed secondary cats my car started smoking as well. I ended up having a vacuum pump installed into crankcase. Smoking was not caused by turbos, oil lines, plugged head or anything else as replaced EVERYTHING including new motor. I always suspected by removing cats there was maybe a lack of adequate back pressure but i couldn't prove this.

Do you have a thread anywhere explaining your setup? The same thing happened to me when I plugged the head and removed rear cats. It was so unbearable that I had the cats welded back in.

 

[Erichale77]

No, I had motor shear a cam bolt hours after install and i sent it out to be rebuilt. Should be getting it back any time now and i'll create a build thread then.

 

[_mpreza]

Spent some time cleaning/pulling apart my car over the weekend and

just about ready to throw in the towel.
I've attached some pics that shows how action packed my weekend was...lol
I've got one last thing id like to do before calling it quits, is it possible to remove the front turbo from the top of the car?
Id like to have a look at whats going on in exhaust valves in cyl 2 (the main culprit) i think that will answer all my/our questions. If turbo cant be removed from the top..... really really cbf removing sub-frame and going down that path.
If someone can confirm it defiantly can be done ill give it a go.
Thanks again! its been good to hear about everyone's experiences/thoughts with similar issues.