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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 > Metal shavings on Intercooler... am I in trouble??



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      06-05-2009, 12:40 PM   #23
Terrance28
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OP return your car to stock completely, take the car to bmw.
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      06-05-2009, 04:12 PM   #24
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You should take your car to the dealer, but isnt your warranty voided because the car was crashed by the first owner and the title was branded as such?
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      06-05-2009, 04:16 PM   #25
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You should take your car to the dealer, but isnt your warranty voided because the car was crashed by the first owner and the title was branded as such?
That could explain shavings in the engine....
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      06-05-2009, 04:23 PM   #26
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+1 that is very useful info. Was the intercooler replaced in the crash? What parts were needed to be replace in the crash.
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      06-05-2009, 07:35 PM   #27
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I just checked my list of "things I would not like to find in my intercooler" and metal shavings was at the top right next to human feces.
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      06-05-2009, 07:52 PM   #28
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Originally Posted by Ilma View Post
Can you clarify.....are you stating that you have been running the car without air filters?

If so, you could have ingested something into your compressor turbine.
It seems like he runs with filter completely removed. Thats no good...no good at all.

The sound is not right as well. I sometimes listen to my turbos whine a bit (only in partial throttle & only under certain circumstances ) but this is extremely much.

I'm afraid its a turbo-related issue.
I wish you all teh best mate ,hope you find a "painless" solution.
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      06-05-2009, 08:10 PM   #29
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yes
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      06-05-2009, 08:19 PM   #30
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WOW...the police siren sound is definitely audible for sure, in fact its the most audible clip that I have heard....metal shavings in the charge pipe is absolutely one of the worst things you can see...Take out all the mods like everyone is saying and take it to a dealership....Driving it now furthur will create even more damage than there is now! Good luck.
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      06-05-2009, 08:45 PM   #31
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Actually I just heard the sound and that is definitely bad. Bad enough it sounds like the Turbos are definitely on their way out. Like someone said, I'd avoid driving the car any more in that condition. Best of luck, hopefully dealer will be helpful.
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      06-05-2009, 11:08 PM   #32
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Are you driving the car without an air filter?
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      06-06-2009, 01:09 AM   #33
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Sounds like your compressor wheel is getting chewed up. That would explain the whining. Use a magnet to check if the shavings stick. If not they are aluminum and your turbo is shot. Oil in the inlet would indicate the turbo journals are going out.

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      06-06-2009, 05:38 AM   #34
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wtf does a ****** charge pipe+bov require you to leave a diverter valve in place,, let alone a vacuum hose on each side.. have had zero problems with the AA.. easy install, 1 vacuum line..

But on to the subject at hand.. metal shavings.. OUCHY! hope u figure out whats wrong and that it wasnt caused by a mod. But the issues you had with the BOV, if you hooked it up wrong theres a possibility that you were puttin some stress on the turbos..

Cause with my AA bov, the vacuum hose somehow got pinched with my shitty running, and it wouldnt release pressure under high boost.. And thats not a good thing.. that pressure has to go somewhere.

but good luck none the less and i hope u get the problem resolved
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      06-06-2009, 05:49 AM   #35
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Yeah more than likely one or both of your turbos are done, this usually causes the whining sound when the turbos are spooling up. The shavings are from the compressor wheel grinding into the turbo housing, you can check for this by pulling the intake hoses off the turbos and visually inspecting the compressor wheels, also wiggle the wheels with your fingers, there should be no side to side play in them.
Hopefully you caught this early enough that no large pieces of the compressor wheel made it into the engine and damaged the valves, pistons and cylinders.
The oil could just be blow by if you're not running a catch can, or it's possible that it's leaking from the failing turbo to.

If you still have a warranty, I would carefully put everything back to stock and let the dealer handle it since repairs will probably be expensive. Don't run the car anymore since the turbo is prone to disintegrating more and getting sucked into the engine now.
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      06-06-2009, 06:08 AM   #36
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I have the same fault codes as you got after IC installed.

and also that whine sound but just not like yours that loud

I wonder if it caused by the way was installed...
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      06-06-2009, 01:56 PM   #37
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Ok, first I cant take to the dealer right now because the car has a branded title so no warranty. and the car only has 500 miles I've been working on it little by little whenever I have some spare time, so it stays in the garage all the time

second, I was only running no air filters during the installation of the BOV and I think thats why the whine was so loud because before with the stock intake, it was not loud at all, I dont know how loud is going to be one I install the AFE system, and I did covered the wholes while I was installing it just so nothing would get inside there.

third, I did replaced the intercooler because the original was damaged, so now Im thinking if the intercooler that I got from someone else had the shavings inside already and they just recirculated thru the air system because of the diverter valves releasing pressure back into the air intake...

today I started the car with the IC off and I was checking to see if there were any shaving coming out the charge pipe, I even rev it a couple of times and everything sounds fine and is pushing air normally...Im still in the process of installing the STETT IC so lets see if maybe it was the because the used Ic had the shaving already in there...

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      06-06-2009, 02:06 PM   #38
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That's crazy metal shavings in your intercooler/intake system.
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      06-06-2009, 02:20 PM   #39
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check to compressor wheels, you won't have to speculate then.
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      06-06-2009, 02:25 PM   #40
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Seems to me that if your turbo compressor was expelling metal, you would find those shavings not just in the intercooler itself, but further upstream in the coupler hose that connects to the "in" side of the intercooler.

You should run your finger along the inside of that coupler hose and see if shavings are present or not.
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      06-06-2009, 02:53 PM   #41
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something got sucked into the turbo, the blades grinded the shit out of it, or the blades got grinded itself, and sent shrapnel to your IC...it has now made its way into the TB, and into your engine...change the oil ASAP and inspect the oil...go to Costco buy a huge bottle of KY...you might need it soon
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      06-06-2009, 03:32 PM   #42
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something got sucked into the turbo, the blades grinded the shit out of it, or the blades got grinded itself, and sent shrapnel to your IC...it has now made its way into the TB, and into your engine...change the oil ASAP and inspect the oil...go to Costco buy a huge bottle of KY...you might need it soon
changing the oil is the least of his problems right now.
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      06-06-2009, 09:08 PM   #43
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changing the oil is the least of his problems right now.


He should change the oil, but not run the car until he inspects the turbo's.

I would pull all the charge piping out and clean it all out as well, might want to pull the intake mani too.
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      06-06-2009, 09:47 PM   #44
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OP was any of the metal shavings in your charge pipe by the throttle body?
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