Oil return line is leaking

[blackms3_71]

Originally Posted by MD1032 Probably just shitty tolerances on the BNR or oil drain line itself (or both). Mine's leaking right now and I bought new gaskets from Mazda. Hopefully that will fix the problem. If not, maybe I'll order some more and double them up like you suggested.

Use cooper spray. That should really help.

[Fonsi]

Originally Posted by MD1032 Probably just shitty tolerances on the BNR or oil drain line itself (or both). Mine's leaking right now and I bought new gaskets from Mazda. Hopefully that will fix the problem. If not, maybe I'll order some more and double them up like you suggested.

Tolerances maybe. Also the holes for the screws may be not deep enough ... nobody knows.

Have you tried using copper spray around the gasket? Maybe that'll work for you.

[Demonspeed2013]

Quick steel that shit ... It works if you don't want to weld it

[aviator79]

Ya im still leaning toward bolts too long for holes/holes not deep enough being the issue.

[Fonsi]

Originally Posted by aviator79 Ya im still leaning toward bolts too long for holes/holes not deep enough being the issue.

I guess its the bolts / holes or the surface is not 100% plane.
But ... as long as the 2 gasket patent is working, I'm not gonna try to find that out

[Fonsi]

Btw .... thanks for helping so far. I had to donate

[Fonsi]

Alright guys, I think I can say: My oil return line is dry now.

What did the trick was using two gaskets between the oil return line and the turbo. I dont like it, but as long as it's dry ....

Edit: did not help. see posts below.

[Funktionull]

Have this same issue. Thought it was fixed but apparently not. Bolts arent bottoming out. I'm not entirely sure it's coming from the return because I see oil higher than that on other stuff like the banjo bolt head for the coolant lines on the side but I guess it could be blowing upward?

[Fonsi]

Did you check the oil feed line? I mistakenly took two different sizes of copper rings when installing it again.

[Funktionull]

I only looked as far as taking the heatshield off and looking at the top of the CHRA to see if there was oil around the feed line and there wasnt. Could have been too hot to stick up there without running down though.

[Funktionull]

Oil feed looks bone dry after driving and the leak itself is so slow that it never actually drips off. I did drill out the bolt holes on the return line instead of using stepdown studs so its possible that I warped the flange enough that it doesnt seal when tightened down even though I sanded it back out to get rid of burs etc.

Going to double up on the gasket this weekend and report back. I can get the material and cut my own I guess?

[Funktionull]

Removed my return line and found a hairline crack in the flange weld on the turbo end.

May or may not be the cause so I'm just going to replace it.

[Fonsi]

Cracks in the flange weld seems to be a common issue too.
I'm glad my return line is try now, I wish you all the best and hope replacing helps you too.

[tokoam]

Had this problem I threw away the crush washer and just used gasket sealant it hasn't leaked since 2 years now going strong

Sent from my SM-A710F using Tapatalk

[Fonsi]

Originally Posted by tokoam Had this problem I threw away the crush washer and just used gasket sealant it hasn't leaked since 2 years now going strong Sent from my SM-A710F using Tapatalk

What gasket sealant did you use?


I have bad news ... my return line is leaking again.
I checked the return line itself with water and it doesn't seem to leak.


I shortened the screws now and used some copper spray around the gasket. Maybe this helps.
Any other hints?

[Funktionull]

Mine ended up being bolts that were a scant bit too long and were bottoming out in the CHRA. They snugged up and the line felt tight by hand so I didnt catch it until I tried everything else.

At one point I doubled the gaskets up and it was dry for a week and then started again. I guess double gaskets were temporarily enough to compensate for the gap from the bolts not being able to tighten the flange down.

Got shorter bolts and still used double gaskets (not sure if it mattered after shorter bolts) and it's dry for like 6 weeks.

[Fonsi]

Originally Posted by Funktionull Mine ended up being bolts that were a scant bit too long and were bottoming out in the CHRA. They snugged up and the line felt tight by hand so I didnt catch it until I tried everything else.

That could be my problem too. I shortened the bolts with a multitool as they had about 0.5cm without a thread at the end. I hope this helped .... I will check my return line in a few days again.

[Funktionull]

Well. My return line is leaking again. I fucking give up. I guess I'm going to throw money at a kozmic line as I have tried everything else I can to make the stock line work.

[blackms3_71]

U want to tighten it to the block then the turbo

[Funktionull]

Thats the way I had to do it. Not because I knew better but because I couldn't get the block end to line up the other way.

It's leaking from the turbo end and had it not stopped for several weeks (In all honesty I stopped checking after it was clean 6 weeks later) I wouldn't even be convinced it was the return line and not the feed.

But I didn't do anything to the feed and it stopped for that long so I can reasonably assume its the return line.

I have swapped the bolts for studs. Swapped those studs for shorter studs. Put a new gasket in, put double new gaskets in. And checked both the flange on the line and the turbo for any deformation that would cause a gap and nothing. Still leaks. I don't know why it was dry for a month and a half and then started leaking. I'm not even convinced it wont leak with a brand new line.

Unless I can piece together a line for less, I may just say fuck it at this point. Shit is coming apart in February anyway.

[Fonsi]

Originally Posted by Funktionull Well. My return line is leaking again. I fucking give up. I guess I'm going to throw money at a kozmic line as I have tried everything else I can to make the stock line work.

Damn ... mine too. Shorter studs did not work for me so I bought some special turbo / exhaust gasket sealant and it was dry for the next 6 or 8 weeks.

I checked it again last weekend and wouldn't believe what I've seen.
Its leaking not that much than before, but still a bit. I think my oil return line might be broken. I'm replacing this shit in fall ... does the Kozmic Oil Return Line fit? They still quote on their homepage:

We will be making an option for the stock turbo soon.

[Fonsi]

Hi guys,

I'm still leaking a decent amout of oil underneath the turbo and I still don't know where it's coming from. It smells like s*it everytime the car is warm and I'm standing still :-/.
I'm replacing the gasket sealant again with the oem gasket and checking the oil feed line washers.

If it isn't the oil feed or the oil return line, what else can it be? The turbo itself? Does an oil restrictor bolt help?

[Funktionull]

I ended up putting another return line on and it didn't help. Looked really close and saw traces of oil between both coolant banjos and the center housing ( where the washer is ).

Since those are both higher than the oil return I assumed the oil wasn't defying gravity and leaking upwards so I checked the oil feed line and apparently missed putting the copper washer between feed banjo and the center housing. Did the one between the bolt and the banjo but forgot the other one somehow.

Replaced it about 200 miles ago and plan to get under the car tomorrow. If it isn't because of that fuck up on my part and it's still leaking it would have to be the seals in the turbo right?

I don't know where else it could come from and just appear on the turbo and nowhere else.

Sent from my SCH-I545 using Tapatalk

[MD1032]

Originally Posted by Funktionull If it isn't because of that fuck up on my part and it's still leaking it would have to be the seals in the turbo right?

No. If those were leaking, you would have oil coming out of the actual inlet or exhaust housings and into the engine/exhaust. Your leak is either the feed or return from the CHRA.

[Lex2007]

Originally Posted by MD1032 No. If those were leaking, you would have oil coming out of the actual inlet or exhaust housings and into the engine/exhaust. Your leak is either the feed or return from the CHRA.

I changed those gaskets and its didn't help one bit. ended up getting a remanufactured OEM turbo. The problem was the seals in the turbo.

[Fonsi]

Damn ... I hope it's not my turbo seals.

[Fonsi]

Turns out, my special "turbo gasket sealant" is not meant to be used directly at the turbo



I now used the gasket that came with the BNR S1 itself...although it leaked with the oem gasket too about a year ago

[MD1032]

Have you tried just using a little bit of permatex black? Messy to clean up and reapply, but might be the only solution for you at this point.

Also be aware silicon will be high in your oil reports for a couple OCI's as it washes out.

[qtrmile beast]

Was going to be one of my solutions. Also the shorter bolt suggestion. I have never seen crush washers used for that area also... Also if all else fails maybe you have too much pressure in the oil return line that is pushing the oil out. So maybe you might want to go to a larger line that will cut down on the pressure. Also if this pressure is great enough it might back up and do damage to your turbo seals in the long run. Also insted of cutting your bolt you could have gotten a washer to put in between the bolt head and the oil return plate.. Same affect just no cutting.. Also you might want to also try using some thread locker because your bolts might be backing out.. doubt that being your problem but it wont hurt..

[Fonsi]

Originally Posted by qtrmile beast I have never seen crush washers used for that area also...

I've talked about the crush washers on the oil feed line ;-). Changed mine today.
With the new gasket on the return line that came with the BNR S1, its still leaking.

I'm going to install a new oil return line and a new oem gasket underneath. After that I'm trying the permatex black. Althouth I'm still not 100% sure that it's the return line itself that is leaking...

[qtrmile beast]

Originally Posted by Fonsi I've talked about the crush washers on the oil feed line ;-). Changed mine today. With the new gasket on the return line that came with the BNR S1, its still leaking. I'm going to install a new oil return line and a new oem gasket underneath. After that I'm trying the permatex black. Althouth I'm still not 100% sure that it's the return line itself that is leaking...

Oh ok i just saw this thread and i scanned through it within 10 mins...lol

[PurplFox]

permatex orange, Meant for the higher heat areas. i Know black is the oil but the temps here get damn hot. red is good to 650 f

[Fonsi]

I'm still not 100% sure if its the oil return line or the turbo itself that leaks somewhere :-/.

I'll try another oil return line today and see if that helps. If not, I'll try the permatex red.
Thank you guys so far ...

[Fonsi]

The oil return line from my MS6 did not help, it's still leaking. Also, when in idle for a few minutes, the car starts to smoke white which makes me think my turbo seals are blown.

I'm now throwing out the S1 and trying to find a turbo specialist in Germany who is able to repair it

[Fonsi]

The BNR is out. I brought it to a local turbo specialist. After a few minutes of disassembling, he told me that the turbo (and the seals) are looking fine.

Now I'm here and I don't know what to do. I have absolutely no idea where the oil is coming from ...

[MD1032]

You sure it's not something silly like a valve cover gasket?

[Fonsi]

Originally Posted by MD1032 You sure it's not something silly like a valve cover gasket?

Unfortunately no ... I'm not sure .
I'm replacing the valve cover gasket these days as I had some oil on my upper spark plug threads.

[qtrmile beast]

if your valve cover was leaking and causing the oil on the underside of the turbo then you will see just as much wetness from the valve cover if not more. Have you tried the permatex yet? also add a small thin washer to the bolts. Also i guess that there is no secretion on the top side of the turbo? Other than that there is no other place for the oil to come from...

The permatex will take care of any uneven surface issues from the drain to the bottom of the turbo. The washer should eliminate the need for a shorter bolt or the current bolt bottoming out.

[Fonsi]

Thank you! I'll keep all that in mind.

I guess I'm installing my old oem K04 turbo again to make sure it wasn't the turbo itself. Although I'm having another problem and I don't know if these 2 problems are related in any matter.
I'm making a new thread about that and link these two threads.

Edit: Light brown oil glibber in my catch can

[blackms3_71]

Have you tried a little higher tq on the bolts?