BPV problem

[The Nut]

I was a beta tester for this initially. Several of the other testers were having an issue with the valve fluttering when letting off the gas after boosting. I was not one of them. When I initially installed it, it fluttered about 3 times, then settled and was functioning properly. But due to the problem that others were having, we were all sent out a revised piston the was machined slightly smaller, and as far as I know this fixed the issue for everyone. When the final product went up for sale, the interior body of the valve was revised to be slightly larger and I haven't heard any complaints. When I received my new piston back then, I swapped it out for the old one as it was supposed to be a better fit. It ran so flawlessly since then (well over a year ago?) that I never bothered to do the every 6 month routine maintenance on it because, like I said, there was nothing wrong with its performance and "If it ain't broke, don't fix it".
But the other night we had a "let's all do compression checks" night at our meet. I did not touch the valve except to disconnect the recirc & that other small vacuum hose to remove my TMIC. When done, I reconnected everything, and when I drove off the valve was fluttering. I attributed this to the fact that engine blow-by oil had kept it lubricated, but had had a chance to drain out enough while the TMIC was off. And so I figured it was due for service anyway.
But now 5 removals off the car, disassembling , clean and re-lube, and reinstall it , and 2 types of grease later (first a very tacky Lucas Oil assembly lube (moly based), and now a white lithium grease) and the damn thing won't stop fluttering. I fully cleaned it each time before re-lubing. The wave spring seems to be in perfect shape, and the piston itself doesn't seem to have suffered any kind of scoring from friction.
I called @CorkSport today and I believe it was Brandon that I spoke to. He had suggested a specific lubricant called Lubriplate 109. This company makes A LOT of different lubricants, but one called 109 is not one I could find, let alone find a place to purchase.
Just to be clear, I have triple checked all hose clamps that were removed the other night, just to be sure it wasn't a leak issue, even though I was sure it wasn't as the car has no problem holding boost. But I am at a complete loss as to what to do to fix it, and from what I understand from researching on here, the valve flutter isn't something that is just annoying or unfortunate. It seems to be something that can cause problems in the realm of permanent damage, and obviously that's not something I need. I've been hesitant to use the first piston it came with since the revised one has never given me an ounce of grief till now, and I don't see why/how it would start to now.
Anyway, didn't want to wait till Monday to try calling CS again so if someone out there has the knowledge and kindness to get me fixed up sooner, I certainly welcome any experienced input, whether from one of you guys (or gals) from @CorkSport or from you gear heads who have successfully troubleshot and fixed this issue in the past.
Thanks for any helpful info ya'll!
-Nut

[Raider]

You have a prototype valve. Not production. Any issues would need to go directly to @CorkSport; since issues you are having may not relate to production units. You never know what final changes were made.

[speedfreak44]

Have you checked other things such as the connections on the hoses going to the bpv and the hoses themselves for small cracks or such? I do not see how a mechanical part just being moved would cause a problem with it. It's not like it's a delicate piece. Did the vacuum port get bumped or bent during the tmic removal/install? Just throwing some ideas out there.

[cam1391]

Yea it diffinately sounds like a split vacuum hose. Try replacing the hose running from the im to the bpv, if its leaking it wont have enough vacuum pressure to hold the valve open, causing it to flutter as air pushes its way through.

[The Nut]

Originally Posted by cam1391 Yea it diffinately sounds like a split vacuum hose. Try replacing the hose running from the im to the bpv, if its leaking it wont have enough vacuum pressure to hold the valve open, causing it to flutter as air pushes its way through.

I'll check that today. I did squish the shit out of that hose when I initially put the TMIC back on. Hopefully the end that is attached to the intake mani isn't too hard to get at. ie: Not having to remove the intake mani.
Many thanks to all 3 of you guys. I'll post how it goes when I'm done.

[JTMS3]

Put the CS bpv on another local's car and see if it acts the same on that car. If so, leave your stock one on and send it back to CS.

[fredricktsang]

I believe they recommended lubriplate 105

[cam1391]

Originally Posted by The Nut I'll check that today. I did squish the shit out of that hose when I initially put the TMIC back on. Hopefully the end that is attached to the intake mani isn't too hard to get at. ie: Not having to remove the intake mani. Many thanks to all 3 of you guys. I'll post how it goes when I'm done.

Its not, I replaced the rubber lines with hard brake line. Took less then 20 mins including running a hard line to the cabin for my boost gauge. Best of luck mate.

[The Nut]

Originally Posted by fredricktsang I believe they recommended lubriplate 105

Maybe I misunderstood him. But I'll be replacing the hose later today to hopefully fix the issue, if not to only eliminate that possibility.

[The Nut]

Vacuum hose replaced, didn't fix problem.

[Brandon@corksport]

Originally Posted by The Nut Maybe I misunderstood him. But I'll be replacing the hose later today to hopefully fix the issue, if not to only eliminate that possibility.

How does the banjo bolt look on top of the bob. Some times those can get damaged and cause a leak, making the valve not operate correctly.

[The Nut]

Originally Posted by Brandon@corksport How does the banjo bolt look on top of the bob. Some times those can get damaged and cause a leak, making the valve not operate correctly.

It looks absolutely fine, but I'll check it when I get home. It's the only part I haven't touched. Thanks for the heads up, I'll let you know how that goes.

[mudrunner2600]

Originally Posted by The Nut I was a beta tester for this initially. Several of the other testers were having an issue with the valve fluttering when letting off the gas after boosting. I was not one of them. When I initially installed it, it fluttered about 3 times, then settled and was functioning properly. But due to the problem that others were having, we were all sent out a revised piston the was machined slightly smaller, and as far as I know this fixed the issue for everyone. When the final product went up for sale, the interior body of the valve was revised to be slightly larger and I haven't heard any complaints. When I received my new piston back then, I swapped it out for the old one as it was supposed to be a better fit. It ran so flawlessly since then (well over a year ago?) that I never bothered to do the every 6 month routine maintenance on it because, like I said, there was nothing wrong with its performance and "If it ain't broke, don't fix it". But the other night we had a "let's all do compression checks" night at our meet. I did not touch the valve except to disconnect the recirc & that other small vacuum hose to remove my TMIC. When done, I reconnected everything, and when I drove off the valve was fluttering. I attributed this to the fact that engine blow-by oil had kept it lubricated, but had had a chance to drain out enough while the TMIC was off. And so I figured it was due for service anyway. But now 5 removals off the car, disassembling , clean and re-lube, and reinstall it , and 2 types of grease later (first a very tacky Lucas Oil assembly lube (moly based), and now a white lithium grease) and the damn thing won't stop fluttering. I fully cleaned it each time before re-lubing. The wave spring seems to be in perfect shape, and the piston itself doesn't seem to have suffered any kind of scoring from friction. I called @CorkSport today and I believe it was Brandon that I spoke to. He had suggested a specific lubricant called Lubriplate 109. This company makes A LOT of different lubricants, but one called 109 is not one I could find, let alone find a place to purchase. Just to be clear, I have triple checked all hose clamps that were removed the other night, just to be sure it wasn't a leak issue, even though I was sure it wasn't as the car has no problem holding boost. But I am at a complete loss as to what to do to fix it, and from what I understand from researching on here, the valve flutter isn't something that is just annoying or unfortunate. It seems to be something that can cause problems in the realm of permanent damage, and obviously that's not something I need. I've been hesitant to use the first piston it came with since the revised one has never given me an ounce of grief till now, and I don't see why/how it would start to now. Anyway, didn't want to wait till Monday to try calling CS again so if someone out there has the knowledge and kindness to get me fixed up sooner, I certainly welcome any experienced input, whether from one of you guys (or gals) from @CorkSport or from you gear heads who have successfully troubleshot and fixed this issue in the past. Thanks for any helpful info ya'll! -Nut

Hey Nut,
This seems odd for the BPV to randomly start having issues, but it's hard to say. Give us a call Monday morning so we can try to troubleshoot this issue together. Sorry for the inconvenience.

FYI: This is Barett, one of the engineers at CS. I don't have an official user name/profile on MSF.

-Barett

[The Nut]

Originally Posted by mudrunner2600 Hey Nut, This seems odd for the BPV to randomly start having issues, but it's hard to say. Give us a call Monday morning so we can try to troubleshoot this issue together. Sorry for the inconvenience. FYI: This is Barett, one of the engineers at CS. I don't have an official user name/profile on MSF. -Barett

Thanks Barett, if screwing with the banjo bolt doesn't fix it, or I find that it's fucked, I'll give you a shout at the office. Now it's time for The Age of Ultron! Now go make yourself a proper profile on here. I don't know if ya heard, but this forum is kinda important to the Mazdaspeed world, and your company dabbles in that....so I hear. 😎

[The Nut]

Not the banjo bolt either. IDK what else to try. I'll hopefully be able to troubleshoot this with CS tomorrow.

[Brandon@corksport]

Ill give you a call here in a little bit!

[The Nut]

Originally Posted by Brandon@corksport Ill give you a call here in a little bit!

Shout out to @CorkSport for going above and beyond to fix my situation. You guys are the best!

[JgamB]

Originally Posted by The Nut Shout out to @CorkSport; for going above and beyond to fix my situation. You guys are the best!

Did you get it sorted? I've been 100% negligent in servicing mine as well because it still vents just as fast as the day I installed it. (non-Beta)

[The Nut]

Originally Posted by JgamB Did you get it sorted? I've been 100% negligent in servicing mine as well because it still vents just as fast as the day I installed it. (non-Beta)

They sure did.

[JgamB]

Originally Posted by The Nut They sure did.

Care to shed any light, just in case I experience anything similar?

[The Nut]

Originally Posted by JgamB Care to shed any light, just in case I experience anything similar?

You have a p.m.

[The Nut]

So....
As it turns out, absolutely nothing wrong with the BPV, only it's idiot noob owner. Not entirely clear why it was never a problem having the vacuum hose routed beneath the cold pipe, but even though it wasn't pinched in any way, it was crimped at enough of an angle to keep it from flowing properly, and therefor causing the valve to flutter. When I had the same issue with the OEM one, I knew something else had to be up. @CorkSport really went above and beyond to help me right the situation, and I'd like to publicly apologize to everyone there that worked to help correct my situation by making me an offer that they did not have to. I hope to hear back from them soon as the ball is now in my court to right the headache I have given them. Thank you for putting up with me @CorkSport.

[speedfreak44]

Why did you route it that way out of curiosity?

[The Nut]

Originally Posted by speedfreak44 Why did you route it that way out of curiosity?

Just always have since the first time my OEM I.C. was taken off (Not by me). It was never a problem, so i just assumed that that was how it was supposed to go.

[speedfreak44]

Gotcha. Well fuck it at least the problem is fixed and yet again corksport goes above and beyond

[Brandon@corksport]

Originally Posted by The Nut So.... As it turns out, absolutely nothing wrong with the BPV, only it's idiot noob owner. Not entirely clear why it was never a problem having the vacuum hose routed beneath the cold pipe, but even though it wasn't pinched in any way, it was crimped at enough of an angle to keep it from flowing properly, and therefor causing the valve to flutter. When I had the same issue with the OEM one, I knew something else had to be up. @CorkSport really went above and beyond to help me right the situation, and I'd like to publicly apologize to everyone there that worked to help correct my situation by making me an offer that they did not have to. I hope to hear back from them soon as the ball is now in my court to right the headache I have given them. Thank you for putting up with me @CorkSport.

Good to here Jason! Ill see what's going on and give you a call in a bit.