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BMW 3-Series (E90 E92) Forum > E90 / E92 / E93 3-series Powertrain and Drivetrain Discussions > N54 Turbo Engine / Drivetrain / Exhaust Modifications - 335i > 1st Track Day = N54 Engine Failure :(



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      03-03-2013, 07:25 PM   #67
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UPDATED 3/3 with pics of replacement N54 (see first page). Will continue to update and post pics throughout week
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      03-04-2013, 10:17 AM   #68
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Originally Posted by SneakyDeeky View Post
UPDATED 3/3 with pics of replacement N54 (see first page). Will continue to update and post pics throughout week
Good luck man. Let us know what happened particularly so we can learn from it.
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      03-04-2013, 10:22 AM   #69
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Good luck man. Let us know what happened particularly so we can learn from it.
this thread makes me sad but subscribed for updates. Hope this works out OK for you OP.
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      03-04-2013, 10:36 AM   #70
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Quote:
Originally Posted by SneakyDeeky View Post
UPDATED 3/3 with pics of replacement N54 (see first page). Will continue to update and post pics throughout week
Did you read the codes?
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      03-04-2013, 02:52 PM   #71
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Originally Posted by jippii ensio View Post
Did you read the codes?
No good trying now.

N54FCK = engine missing

Lol
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      03-04-2013, 03:12 PM   #72
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Quote:
Originally Posted by crypticc View Post
No good trying now.

N54FCK = engine missing

Lol
Its too early for that kind of humour

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      03-04-2013, 03:28 PM   #73
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Oh that sucks. Good luck.

I cannot imagine all involved in swapping the engine in these cars and getting every little connection back.

Time to go to Shiv single big turbo
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      03-04-2013, 05:20 PM   #74
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Yeah sorry
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      03-04-2013, 05:25 PM   #75
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Subscribed for details on the teardown. I doubt it was an injector issue. And even not knowing anything about the oiling of this engine, I'd still doubt oil starvation. You'd have to be on slicks and killing it plus you'd hear some pretty awful rod knock first.

Did you break the clutch? If you were WOT and your clutch shattered, that could cause some dramatic changes in load on the crank. Maybe the engine over-revved? When's the teardown?

Side question: Does anyone know if you can get real-time oil pressure using the torque app? Is there an oil pressure sensor or just an oil pressure switch?
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      03-05-2013, 01:17 AM   #76
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SUB'd for teardown pictures/details.

Just a little thinking out loud here: I doubt it was a tune or meth related failure. Even on ACN the DME can handle 14psi@stock timing like a champ. I've seen more than a couple logs of cars having multiple cylinders making 7+ degree corrections at a time and zero issues as a result. In no way am i ever suggesting relying on the DME as a failsafe but shit happens and the DME programming probably saves engines on a daily basis.

The injector stuck open sounds plausible. Large amounts of raw fuel could easily result in a loud explosion, plume of white smoke and engine failure. I actually had the same thing happen to a F150 i had a few years back.

Also, can't really rule out a failure in the top end. Valves are dropped all the time, we're just blessed to have an engine that is mechanically a tank and we don't see that stuff happening(yet...)
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      03-05-2013, 10:49 PM   #77
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UPDATE #2: 3/5 - Engine removed and root cause identified; hydrolock caused by methanol injection malfunction


Today the failed engine was removed from the car and the cause was identified without even needing to tear the engine apart... excessive methanol injection caused hydrolock which resulted in a hole blown through the bottom end of the long block on the driver side. CRAZY!

This is what I saw when I walked in the shop on my way home from work...



I hope I never see this again...





Failed engine removed from the car (below)



Note the Lamborghini Gallardo in the background



Hole blown through the driver side of the longblock above the oil pan, near the rear of the engine (closer to cylinder 6, farther from cylinder 1)





Chunks of metal were removed from the oil pan and fragments were found in the oil filter (below).





This means my ER dual oil coolers need to be flushed to ensure there's no remaining metal floating around in my oil lines.





Also, still need to inspect the turbos off my failed engine to ensure they're good to re-use on the new engine. I'd prefer to keep them as they only have 12,000 miles on them, whereas the new engine and turbos have ~27,000 miles. Turbos off of replacement engine and various spare parts shown in picture below as the replacement engine is being prepped for transplant surgery (i.e. - carbon buildup being removed and major cleaning to ensure all metal fragments removed).



Mechanic said there were still puddles of pink "boost juice" (pre-mixed methanol and distilled water in 49/51 ratio) inside the cylinders when he first gained access to the intake manifold. Basically, a smoking gun that the engine failure was caused by excessive methanol injection, which resulted in hydrolock. As far as what caused the methanol injection to malfunction, I have no idea. All I know is that my confidence in the BMS Methanol Injection kit is gone. I plan on ditching methanol completely and switching to a more track-friendly tune once my car is back up and running. Mechanic plans to have my car running by Friday (3/8).

Of all the people using JB4 and its functionality as an integrated methanol injection controller, I guess I'm the first lucky one to have this happen.
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      03-05-2013, 10:54 PM   #78
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Wow I didn't expect that particularly, at least you know conclusively what the issue was. Crazy amounts of material in the oil filter!
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      03-05-2013, 11:01 PM   #79
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Sneaky, you may have better luck with the turbo's from the new motor. Reason I say this is your contaminated oil probably reached the turbo's bearings and screwed them up. Keep this in mind, because I would hate to have you button everything up and have issues.

I'm sorry for the loss. It was out of your control, but things happen and I wish you luck. My buddy just lost a motor in his 6.0 powerstroke, due to a lifter failure. It's amazing how the small things often lead to these types of failures.
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      03-05-2013, 11:13 PM   #80
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Sucks about the meth kit. If you go back to meth, look into Cobb with aqua mist HFS4, it disables methanol injection for under OR overflow condition and dumps boost via the waste gates as an additional fail safe.
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      03-05-2013, 11:14 PM   #81
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Sneaky, you may have better luck with the turbo's from the new motor. Reason I say this is your contaminated oil probably reached the turbo's bearings and screwed them up. Keep this in mind, because I would hate to have you button everything up and have issues.
Mechanic and I discussed this today and he's going to do a thorough examination prior to install. Based on how the failure occurred, he thought there was a good chance the turbos stopped spooling prior to any metal shavings circulating through the oil line. Any concern or sign of metal fragments will cause us to use the higher mileage turbos that came with the replacement engine. Who knows, maybe RB turbo upgrade later?
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      03-05-2013, 11:18 PM   #82
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This is interesting. What controls the methanol flow though, isn't it the BMS Solenoid? I think there must be a specific part in the system that failed to allow this to happen. Would be nice if Shiv or Mike could chime in.

I'm concerned because I am running the same system among probably hundreds of other people and I will have to upgrade parts or change things prior to Vargas stage 2.
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      03-06-2013, 09:55 AM   #83
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one of the reasons i would never skimp on a methanol system if you choose to run it.

Aquamist or nothing. I paid over $1,000 for my system alone with no tank, its worked flawlessly and Jeff Howerton is a genius with the systems. Doesn't get any better.
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      03-06-2013, 09:57 AM   #84
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Never would have guessed this result. I had no idea a failure mode would push that much meth and then only into one cylinder.
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      03-06-2013, 10:03 AM   #85
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Just replace the oil coolers, you will never be able to flush them out 100%
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      03-06-2013, 10:03 AM   #86
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Quote:
Originally Posted by ajsalida View Post
Never would have guessed this result. I had no idea a failure mode would push that much meth and then only into one cylinder.
it wasnt into one cylinder, but thats the one that gave up the ghost and quit firing, i'm sure the others saw crazy amounts of meth too.

oh, by the way guys, have you ever put your meth pumps on 100%DC and flowed into a bottle? My aquamist pump can fill the bottle up in a few seconds.....this gives you an idea of how this can kill an engine thats on decel (not firing).
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      03-06-2013, 10:07 AM   #87
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Originally Posted by Sniz View Post
it wasnt into one cylinder, but thats the one that gave up the ghost and quit firing, i'm sure the others saw crazy amounts of meth too.

oh, by the way guys, have you ever put your meth pumps on 100%DC and flowed into a bottle? My aquamist pump can fill the bottle up in a few seconds.....this gives you an idea of how this can kill an engine thats on decel (not firing).
OK that makes more sense. I had no idea those pumps flowed that much.
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      03-06-2013, 10:17 AM   #88
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so you were using the FSB ?
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