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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 > *Wastegate Ticking Noise Found*



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      04-10-2008, 03:38 PM   #133
Jake C
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Thanks Mr. 5

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      04-10-2008, 10:20 PM   #134
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I purchased a couple C clip washers the other day.
I picked the washer that looked like it was the best fit, but I had to sand down the washer a bit to make the width of the washer the same as the gap that I have.

I then stuck the C clip in place.
I made sure that the wastegates were still able to function (move back and forth) correctly.

I started up my car and the ticking has disappeared.
I revved up the engine and no ticking. (I previously did this with a putty knife, but the c clip is going to take the permanent approach for now)

I understand that this is a band aid and not the real fix.
I'll see if the ticking reappears. If it comes back and the C clip is still there then there is something that is becoming looser and looser inside the exhaust part of the turbo.

I'll take videos tomorrow so you can hear how the ticking has finally stopped.
...Finally tried the C clip I suggested...seemed like the obvious fix to me. So what if its a bandaid. I doubt you'll have the problem again. If it comes back you're right it is something else. Glad its fixed. Did you put the C clip at the rod/teardrop assembly and NOT the gold part?

If so....You owe me a beer....
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      04-10-2008, 10:43 PM   #135
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      04-11-2008, 07:09 PM   #136
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Here's the vid that I took today.

No ticking!

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      04-12-2008, 02:10 PM   #137
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      04-12-2008, 05:37 PM   #138
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Quote:
Originally Posted by Mr. 5 View Post
For me, it was only the linkage of the rear wastegate that was loose, so I only needed one washer.

Remember though that for right now I am calling this a temporary fix.
If the linkage never becomes any looser in the future then this will be a permanent fix until I decide if I ever want this matter addressed by BMW.

If I would have gone into BMW when I first heard this problem, they would have replaced my wastegate actuators, but based on what I found, new wastegate actuators would not have fixed the problem.

They need to replace the exhaust portion of the turbo that includes the actual wastegate.
Mr. 5: can you post a picture of exactly where you've placed this washer?

Thanks,
Rob
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      04-12-2008, 05:43 PM   #139
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Useful thread, nice job!
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      04-12-2008, 09:42 PM   #140
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Hey Mr 5...Can you post up the gap pics of the before and after your c clip fix, it would give us a better understanding of what u did and how it fixed that gap...I know hearing your video there is a significant difference, but can you post up the pics of where u place the c clip..
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      04-12-2008, 09:51 PM   #141
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Quote:
Originally Posted by cn555ic View Post
Hey Mr 5...Can you post up the gap pics of the before and after your c clip fix, it would give us a better understanding of what u did and how it fixed that gap...I know hearing your video there is a significant difference, but can you post up the pics of where u place the c clip..
+1 i want to print out the before and after pics and show them to my dealership, cause they apparently have no idea how to fix my car after taking it 3 times to them.
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      04-12-2008, 11:27 PM   #142
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Quote:
Originally Posted by cn555ic View Post
Hey Mr 5...Can you post up the gap pics of the before and after your c clip fix, it would give us a better understanding of what u did and how it fixed that gap...I know hearing your video there is a significant difference, but can you post up the pics of where u place the c clip..
Here you go. I was messing around with c clips but I was having a hard time filing down the clip to the perfect width to match the space that I have. This is why I went with the feeler gauges instead. The before pic is on the first page.

Quote:
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+1 i want to print out the before and after pics and show them to my dealership, cause they apparently have no idea how to fix my car after taking it 3 times to them.
Do it man, because I'm so fricken stoked right now.
This is what I did that is proven to work.

-I went to Harbor Freight and got a cheap set of Feeler Gauges.
-I found the measurement of the space that I have (In my case, I have a space of .43 mm)
-I cut a piece of the .43 mm feeler gauge.
-I cut a "U" piece out of the feeler gauge so the "shim" will fit around the rod that is connected to the wastegate.
-Make sure that the shim is not too tight or the wastegate will stick and this is not good.
-Now start your car, rev it up, exit the car, and jump up and down because you will here pure engine and no ticking.



I went driving after the feeler gauge was installed. I drove it hard and I drove it soft. I made sure the engine was hot. I got gas and I checked the wastegate rod before and after I turned the engine off to make sure the rod was moving. I went a couple more places and the same thing.
I'll keep checking for the next week here and there to make sure everything's still working alright.
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      04-12-2008, 11:30 PM   #143
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Good idea on thinking outside the box, Mr. 5!

For the local guys.......drive to Mr. 5 BMW to get it done. JK.
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      04-12-2008, 11:33 PM   #144
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Good idea on thinking outside the box, Mr. 5!

For the local guys.......drive to Mr. 5 BMW to get it done. JK.
Yep, I'll charge $200 per person.
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      04-12-2008, 11:48 PM   #145
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Here's what my shim looks like that fills up my space.
This isn't the exact one that's in my car, but they look identicle.
I made this one but this was from a feeler gauge that was .48 mm thick and I couldn't even move the wastegate.
This is why I stressed about if the shim is too thick.
It could stick or the wastegate won't move like it was intended to.
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      04-14-2008, 11:00 AM   #146
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Hey AU335,
Please let us know what happens when you go back to the dealer with this.
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      04-14-2008, 11:22 AM   #147
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Quote:
Originally Posted by Mr. 5 View Post
Hey AU335,
Please let us know what happens when you go back to the dealer with this.
Definitely will do! Headed there this week
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      04-14-2008, 11:29 AM   #148
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Definitely will do! Headed there this week
I'm so stoked man!
Seriously, It sounds like someone gave me a brand new engine.
Soooo smooth!
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      04-14-2008, 11:48 AM   #149
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Here's a thread on the factory fix.

http://www.e90post.com/forums/showthread.php?t=133464
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      04-14-2008, 12:22 PM   #150
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Here's a thread on the factory fix.

http://www.e90post.com/forums/showthread.php?t=133464

If you have read this thread then you would have known that the dealer fix would have not fixed my problem.
If the dealer would have replaced both actuators on my car, the ticking would still be there. My actuators are completely fine.

If you have the same exact problem as me then you're going to wait a week for them to repair it, get into your car and still hear the ticking noise.
Or, they will have your car for much longer because they won't know what to do except for replacing the eintire turbo/exhaust section.
Here's what I posted earlier in the thread, which includes the TSB:
http://www.e90post.com/forums/showpo...6&postcount=79

I responded in your thread, but the fix that you showed is not my problem.
My problem is due to the linkage of the actual wastegate coming loose.
It has nothing to do with the wastegate actuator.
I truly believe that BMW is not getting it right here.
I have a feeling that other people are having the same problems as myself.
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      04-14-2008, 12:46 PM   #151
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My problem is due to the linkage of the actual wastegate coming loose. It has nothing to do with the wastegate actuator. I truly believe that BMW is not getting it right here. I have a feeling that other people are having the same problems as myself.
We have the exact same problem, that's why I inserted the cross link to the new "fix" thread. The fix according to the repair sheet my SA showed me this morning is replacement of both front and rear wastegate actuators and actuator arm assemblies.

Maybe I'm missing something here, but I don't think so. I'll post the outcome of this fix when I get the car back. I hope they got it right.
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      04-14-2008, 01:36 PM   #152
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I really don't see how they can repair the actuator arm since the arm is welded to the actual wastegate rod that rotates the wastegate.
The arm is welded to the rod (first pic) and the wastegate is pressure fit to the rod on the inside of the turbo (second pic yellow arrow).
Check out the pics.
The yellow arrow is indicating a spot that I thought might have been adjustible, but there is nothing to adjust.

This is why I'm thinking that the only fix would be getting a complete new turbo.
Hopefully I'm wrong.

I'm going to wait for more and more people having this problem so I can make sure that I know exactly what's going to happen, and I will be assured that the problem will be fixed in a timely manner.

Quote:
Originally Posted by BKLYN335xi View Post
We have the exact same problem, that's why I inserted the cross link to the new "fix" thread. The fix according to the repair sheet my SA showed me this morning is replacement of both front and rear wastegate actuators and actuator arm assemblies.

Maybe I'm missing something here, but I don't think so. I'll post the outcome of this fix when I get the car back. I hope they got it right.
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      04-14-2008, 02:34 PM   #153
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Great pics. I'm wondering if a large chunk of the 16 hours is remachining the turbo with an entirely new wastegate. Even giving 4 hours to remove and reinstall both turbos would leave 6 hours for each turbo for machining.

BMW must be trying to avoid the cost of supplying and replacing 10,000+ turbos.
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      04-14-2008, 03:00 PM   #154
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I don't know.
I didn't think that they were replacing the wastegate arms.
I thought they were only replacing the wastegate actuators.
Let us know.

Quote:
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Great pics. I'm wondering if a large chunk of the 16 hours is remachining the turbo with an entirely new wastegate. Even giving 4 hours to remove and reinstall both turbos would leave 6 hours for each turbo for machining.

BMW must be trying to avoid the cost of supplying and replacing 10,000+ turbos.
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