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The BMW Range
3 Series
E90, E91, E92, E93
E92 335i wastegate rattle and 30FF DME
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<blockquote data-quote="OCD" data-source="post: 746148" data-attributes="member: 48808"><p>Hello all. Finally an update on resolving the issue.</p><p></p><p>I've been busy with business travel and thought it would be a good opportunity to put the car in the workshop for some serious troubleshooting.</p><p></p><p>Decided to drop the engine and do a thorough check on all the engine components.</p><p></p><p><a href="http://s1279.photobucket.com/user/steveljw/media/IMG-20161124-WA0068_zpsm8jkmcbh.jpg.html" target="_blank"><img src="http://i1279.photobucket.com/albums/y523/steveljw/IMG-20161124-WA0068_zpsm8jkmcbh.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a></p><p></p><p>Took out the turbo/wastegate assembly and the rattlling is very serious. Flapper and bushings are so loose that they ring like a bell when I shake the housing. Fortunately the turbos are still in good condition.</p><p></p><p>Decided to order a wastegate repair kit from Turbo Lab US to replace the worn out parts.</p><p></p><p>Before this I've changed all my vacuum hoses to silicone ones to ensure there's no vacuum leak. Checked the vacuum canisters as well and they're still in good condition.</p><p></p><p>At the same time, realized that my engine mountings are failing and got them replaced. Some ageing power steering components are replaced as well.</p><p></p><p>Noticed the intake tract and valves are in a mess with lots of carbon deposits. Decided to do a thorough clean up using the manual way.</p><p></p><p>After fixing back all the parts and test driving the car, we found that a MAP sensor is defective. And a boost solenoid is bleeding boost. Got them replaced and so far the car is running great. Power delivery is much smoother now and the response across all RPM range is great. Not a hint of lag at all.</p><p></p><p>Hope this info is useful for those affected. It's such a shame that design issues like this are overlooked by the BMW engineers. Otherwise, the 335 is an amazing ride! :67: </p><p></p><p>Some pics and vids of the new wastegate parts after the machining work:</p><p></p><p><a href="http://s1279.photobucket.com/user/steveljw/media/IMG-20161117-WA0012_zpsuakezrkf.jpg.html" target="_blank"><img src="http://i1279.photobucket.com/albums/y523/steveljw/IMG-20161117-WA0012_zpsuakezrkf.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a></p><p></p><p><a href="http://s1279.photobucket.com/user/steveljw/media/IMG-20161117-WA0013_zpshk2cacny.jpg.html" target="_blank"><img src="http://i1279.photobucket.com/albums/y523/steveljw/IMG-20161117-WA0013_zpshk2cacny.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a></p><p></p><p><a href="http://s1279.photobucket.com/user/steveljw/media/IMG-20161117-WA0014_zpshtfeisxj.jpg.html" target="_blank"><img src="http://i1279.photobucket.com/albums/y523/steveljw/IMG-20161117-WA0014_zpshtfeisxj.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a></p><p></p><p>[media]https://www.youtube.com/watch?v=mQQ-kNmMXSM[/media]</p><p></p><p>[media]https://www.youtube.com/watch?v=upOOGwQcF0Y[/media]</p></blockquote><p></p>
[QUOTE="OCD, post: 746148, member: 48808"] Hello all. Finally an update on resolving the issue. I've been busy with business travel and thought it would be a good opportunity to put the car in the workshop for some serious troubleshooting. Decided to drop the engine and do a thorough check on all the engine components. [URL="http://s1279.photobucket.com/user/steveljw/media/IMG-20161124-WA0068_zpsm8jkmcbh.jpg.html"][IMG]http://i1279.photobucket.com/albums/y523/steveljw/IMG-20161124-WA0068_zpsm8jkmcbh.jpg[/IMG][/URL] Took out the turbo/wastegate assembly and the rattlling is very serious. Flapper and bushings are so loose that they ring like a bell when I shake the housing. Fortunately the turbos are still in good condition. Decided to order a wastegate repair kit from Turbo Lab US to replace the worn out parts. Before this I've changed all my vacuum hoses to silicone ones to ensure there's no vacuum leak. Checked the vacuum canisters as well and they're still in good condition. At the same time, realized that my engine mountings are failing and got them replaced. Some ageing power steering components are replaced as well. Noticed the intake tract and valves are in a mess with lots of carbon deposits. Decided to do a thorough clean up using the manual way. After fixing back all the parts and test driving the car, we found that a MAP sensor is defective. And a boost solenoid is bleeding boost. Got them replaced and so far the car is running great. Power delivery is much smoother now and the response across all RPM range is great. Not a hint of lag at all. Hope this info is useful for those affected. It's such a shame that design issues like this are overlooked by the BMW engineers. Otherwise, the 335 is an amazing ride! :67: Some pics and vids of the new wastegate parts after the machining work: [URL="http://s1279.photobucket.com/user/steveljw/media/IMG-20161117-WA0012_zpsuakezrkf.jpg.html"][IMG]http://i1279.photobucket.com/albums/y523/steveljw/IMG-20161117-WA0012_zpsuakezrkf.jpg[/IMG][/URL] [URL="http://s1279.photobucket.com/user/steveljw/media/IMG-20161117-WA0013_zpshk2cacny.jpg.html"][IMG]http://i1279.photobucket.com/albums/y523/steveljw/IMG-20161117-WA0013_zpshk2cacny.jpg[/IMG][/URL] [URL="http://s1279.photobucket.com/user/steveljw/media/IMG-20161117-WA0014_zpshtfeisxj.jpg.html"][IMG]http://i1279.photobucket.com/albums/y523/steveljw/IMG-20161117-WA0014_zpshtfeisxj.jpg[/IMG][/URL] [media]https://www.youtube.com/watch?v=mQQ-kNmMXSM[/media] [media]https://www.youtube.com/watch?v=upOOGwQcF0Y[/media] [/QUOTE]
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E92 335i wastegate rattle and 30FF DME
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