My name is Bryan Nickell and I am a Newbie to the mazdaforums. Some of you may have heard of BNR Supercars, some may have not.
I was approached by an RX7 person that had a Mazdaspeed 3. He told me about all their problems with turbochargers and companies offering an unreliable product. So I bought some turbocharger cores and determined cause of problems.
Since I joined S U F and also MS6F, I really saw a need that had to be met. Mazda really needs my help, but I have to be some establishment like Garrett, IHI, MHI or whatever to get contracts with Mazda. I can understand thier point but KKK isn't going to find or fix the existing problems. I went pretty high up in the Mazda Head Quarters but I have to be a big corp in order to get a manufacturing contract with them.
I guess Mazda will just have to replace millions of dollars worth of junk turbos, just to turn around and do it again. Then when warranty runs out, its on the consumer. Thats the point of them finding solutions, they hope they bandaid the real problem until its out of warranty...
Bolt Up Replacement Turbocharger Upgrade
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Originally Posted by Bryan@BNR
Hello all.
There is a big problem with the turbochargers on the MS3/6/cx7. I have taken apart a bunch of them and this is what I find...
The turbo is a KKK K04. The smoking problem is b/c of a combination of several things.
weak crank case ventilation
too much oil pressure
not enough backpressure to equalize crank case pressure
improper tolerances in turbocharger
We all know mazdas fixes. CCV update, synthetic oil change, oil restriction, and also their turbo replacement. All of which is not going to solve their issues 100%.
I take apart these turbochargers and I see something right off the bat that is waaaay out of wack. The compressor seal is nearly .012"! This tolerance is supposed to be .0025-.003".
What is happening is the boost from the compressor housing is blowing into the bearing housing through that gap and causing the oil to not flow properly to the oil pan. The oil backs up and the level rises in the bearing housing of the turbocharger until it leaks through the turbine seal which is on the exhaust side that has a gap of .010". When it seeps through that gap, it enters the exhaust system causing your smoking...
I have a fix for the issue and it requires a build up of the turbocharger. It has a total seal on the compressor side so no boost enters the crank case! Not to mension a reliability increase and performance increase.
Bryan@BNR