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Old 01-11-2009, 12:08 AM   #1
DriftIt
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'05 WRX

Default Fuel smell/white smoke and oil (something wet) leak from turbo after up-pipe install

Here's the rundown. We did an aftermarket up-pipe install on my gf's '04 WRX (2.0L, 5spd MT). Prior to the install I noticed when she drove it hard (under heavy to w.o.t.) that after she let off the gas there would be a smell for a few seconds that smelled like burning oil. When I was following her in my car I also noticed a very faint puff of bluish/whitish smoke that looked like it came from the exhaust when she got on it hard and then let off.
Power mods before the up-pipe install are as follows (afaik):
-Invidia catless down-pipe
-Custom cat-back exhaust with magnaflow muffler
-Cobb AccessPort v1 Stage 2 (Pro-tuned by local tuner).
(still had catted UP)

To install the up-pipe we removed the DP and loosened up the two brackets on both sides of the turbo, removed the pass. side manifold O2 sensor, took off the necessary heat shields, removed the EGT sensor, loosened the turbo inlet hoses so we had some wiggle room and were able to get get the up-pipe wiggled around enough to where we could get it to come around behind the turbo, spin the UP around and pull it out the bottom where the DP was. I noticed the oil return tube popped out of the top of the hose it goes into but made sure it was back in place and the clamp in the proper position when we went back together with the new UP.

The installation of the aftermarket UP was fairly easy. It was a used, solid UP (no flex section), no EGT bung, but in good shape and was already heat wrapped. We used the new Grimmspeed thick, crush style gaskets on both ends of the UP and for the turbo>DP gasket and torqued to spec at all locations that had been disconnected.

Upon taking the car for a drive I noticed oil smell was heavier and there was a little smoke coming from underneath the turbo/DP location when I popped the hood but that the smoke eventually went away after a couple short drives. No funny noises, just that oil smell when you got heavier into boost. When I got back from the drive there were a couple drops of oil (or something dark/liquid) on the edge of the UP flange where it meets the turbo and it looked like a little oil on the bottom/middle of the DP flange where it bolts to the turbo. Immediately I thought "that damn oil return line!". Well.. I still had the heat shield off and was able to get a clear view of the return line and top and bottom were completely dry on the outside, so it doesn't look like that was the problem. I'm thinking its either be something to do with the turbo and maybe the DP didn't seal, with either a bad turbo oil seal + turbo>DP gasket is leaking and oil (or condensation/carbon) is leaking at that location OR some fitting that I'm not seeing is leaking on the outside and flowing along the top/inside edge of the UP flange and dripping off the back of the flange onto the CV boot. The car is also emitting very rich smelling exhaust and thick whitish smoke/condensation for the first few minutes of running and a slight oil burn smell when you rev it hard and let off quickly. Also noticed the liquid (whatever it is... oil, etc.) dripped a couple times on the inner CV boot but that boot looked pretty greasy on the outside before the UP install.

My question is, what could this oily looking liquid be leaking from? Is the turbo seal taking a crap and the DP didn't seal? And why would it be this bad after installing the up-pipe? We didn't actually remove the turbo from the car and all banjo fittings/lines were left completely connected throughout the removal/install.

Oh!.. I just remembered a couple other details. I pulled out the rear 02 sensor after a few test runs and it looked like it was dry (no oil or liquid of any kind on it) and was the regular light brownish color that a normal 02 sensor would have, which would support my idea that there's a fitting or something leaking on the outside of the turbo that I'm not seeing. Also when I first start up the car there's a lot of condensation that comes out the muffler but it evaporates off the concrete very quickly and not much cabon deposit. I'm pretty sure the whitish exhaust fumes are not coolant, I know what a bad head gasket/coolant in exhaust smells like and it doesn't have that sweet smell at all.

Help! I feel bad cuz this is my gf's daily driver and I don't want a little oil leak to cost her a turbo or a motor. Thanks in advance for advice/suggestions.
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Last edited by DriftIt; 01-11-2009 at 12:15 AM.
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Old 01-11-2009, 12:11 AM   #2
DriftIt
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I'll try to take a couple of pics tomorrow of where the oil/liquid is showing up on the UP/DP and post them.


..edit.. just remembered a couple other details as far as how the car runs. Boost climbs quickly and holds solid at peak boost and idle is steady.

Last edited by DriftIt; 01-11-2009 at 12:34 AM.
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Old 01-11-2009, 12:45 AM   #3
Kaldar142
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smoking from the engine bay is just all the chemicals and whatnot burning off, fuel smell may be due to going to a catless uppipe.
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Old 01-11-2009, 12:48 AM   #4
DriftIt
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What about the oily liquid on the UP/DP flanges? Is that from the inside of the turbo or a line on the outside that I'm not seeing?
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Old 01-11-2009, 12:48 AM   #5
Kaldar142
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from the sounds of it though, it sounds like you def. have a leak in the turbo-area, i would double check ALL lines.... those leaks in that area can be a PITA, i had a coolant smell for the longest time that i couldn't figure out where it was coming from. turns out it was the coolant line to the turbo was ever so slightly leaking lol
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Old 01-11-2009, 12:52 AM   #6
Kaldar142
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btw after working at a dealership for a while now... when trying to diagnose leaks like that... brake clean is your friend
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Old 01-11-2009, 12:05 PM   #7
DriftIt
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I'll try cleaning it up again and see if I can pinpoint the leak. I'm hoping we didn't somehow crack a fitting on one of the oil lines when we were wiggling the turbo up enough to get the UP out..
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Old 02-17-2009, 03:28 AM   #8
starcraft227
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I have the white smoke coming out under the area where the up pipe connect to the header. I just installed a 16g, and start the car. the temperature was a bit cold. When it fired up, I notice a bunch of white smoke coming from lower area of up pipe. after 5 mins of idle, most of them are gone, but still a tiny smoke that came from the uppipe join turbo.It's look like a leak right there to me, but double check everything just to make sure.
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Old 02-17-2009, 03:37 AM   #9
ejpowerguy
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sounds like a blown turbo. When the thrust "bearings" start to give and the seals go you will get oil coming out in all kinds of places. may be the blue smoke seen in between shifts also.
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