Hello one and all.

yesterday I decided to fit a performance airfilter to my 115bhp Stilo mainly because I was fitting a new MAF and the clips on the Air Box had rusted to nothing.

I took the front cover off the air box and my filter was well caked up with flys and so was the mesh on the old MAF so perfect time for a change. My old MAF seemed to be caked in oil.

I took the rubber hose off the turbo , fitted a new section of pipe then a new Bosch MAF then a K&N filterwhich pokes into the old air box just under the cold feed.
The breather hose from the rocker cover was spliced and connected to the tank on the bottom of the air box.

Then the problems started, on start up my car was suddenly putting out loads of white smoke with a smell of burning oil????
Enough smoke to mean it cant be driven on the road.
I ran out of daylight by this time so went out again today and the smoke is less but big plooms when you rev the engine.
i took everything off that I put on yesterday and no change. Whilst there I put my fingers in the turbo and its spinning freely and there is no end float movement in the shaft. Put everything back together and checked I hadnt knocked something whilst in the engine bay but all seems in order.
Smoke has a slight blue tinge.
On tickover the car is perfect and drives fine but when the turbo winds up you can here what sounds like a loud scraping noise. Also when the engine is turned off there is sometimes a hissing,sizzling noise from the turbo area like the sound of water poured on hot metal.

Im baffled especially as the turbo seemed to be running freely , also until I changed the airfilter the car had never had such a problem.
May be coincidence its happened when I changed the filter or maybe the increased airflow has shown something up.

ANY IDEAS ??

I took the rubber hose off the turbo , fitted a new section of pipe then a new Bosch MAF then a K&N filterwhich pokes into the old air box just under the cold feed.

what have you fitted? a new panel filter in the airbox? or a cone type filter on some silicone hose to turbo?
if its the latter is your breather still 't'd into the turbo inlet? if not where is breather going now? if blocked off breather overpressure may cause oil seepage from turbo
any chance of foreign object damage when you removed maf , a small piece of plastic missing off old maf?
have you got the right maf? could it be over fuelling smoke whats it like with new maf disconnected.

the maf housing can be a slight pain to get out with alot of force and strain on the ducting leading to and connected to the turbo, Is it possible in removing it you have damaged a seal or something similar at the turbo?

Ive fitted a K&N cone filter so basically my standard airbox is still on the car but I have removed the front cover so the cone filter pokes into the airbox just under the cold feed from the front of the car.

I have removed the rubber hose which connected the maf to the turbo. This hose had a pipe going into it from the rocker cover then a pipe coming out of it to an oil trap on the bottom of the airbox.
Since I removed this and still wanted the rocker cover pipe feeding into somewhere for any oil coming out I connected the pipe from the rocker cover to the pipe that leads to the trap on the bottom of the airbox. This means the rocker cover breather pipe now does not connect into the induction pipe at all , just bypasses straight to the trap.
I wanted to do this because my old MAF was getting oiled up seemingly from gunk coming from the rocker cover pipe.
in preperation for this work I had a full engine flush and oil/filter change done a couple of weeks ago and everything was running fine.
I bought the correct Bosch MAF for my car but even if I hadnt I have ran the car both with the MAF on and without ,to see if the MAF was the problem, and still the same problem.

When I took the old maf off I disconnected it from the turbo link hose then removed it from the cover of the airbox then the airbox cover itself so cant see how I could damage the turbo.
When I took it all apart again today I checked averything I could and couldnt see anything I could of damaged and all other connections seem to be fine.
I was expecting movement on the turbo centre shaft or scraping whilst spinning the impellar by hand but not getting any of that. It all felt as it should.

The noise seems to happen when I lift off and the turbo is winding back down