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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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      06-06-2009, 11:23 PM   #45
Turkishexpress
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Originally Posted by ****** View Post
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...
You might have bit off a little more than you can chew with this car bro. Like its been said drain your oil and check for shavings immediately both in the pan and the oil filter. Use a magnetic pan if you can. You need to make sure that the oil is not contaminated before you keep starting your car. Also, stop starting the car without completing the circuit (such as starting it without the ic on and revving it). Its really not going to tell you anything besides the car throw all kinds of codes.

If there are shavings in the oil you drained you may be screwed...

If there are no shavings, you will need to check and verify that there is no turbo damage. Preferably both from the cold and hot sides. If there is you got a lot of work to do...

If everything checks out then you need to clean out the piping and count your lucky stars.

Good luck!
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      06-07-2009, 03:37 AM   #46
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How would the metal shavings make their way into the oil?
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      06-07-2009, 10:45 AM   #47
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How would the metal shavings make their way into the oil?
good question, I've been asking myself that...
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      06-07-2009, 04:48 PM   #48
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good question, I've been asking myself that...
Even if the shavings got sucked into the combustion chamber, wouldn't they have to make it past the rings to get into the oil in the crankcase???
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      06-07-2009, 05:53 PM   #49
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Even if the shavings got sucked into the combustion chamber, wouldn't they have to make it past the rings to get into the oil in the crankcase???
I beleive that is the case... If that happens, you would know something was wrong with the engine as the compression would go to hell.
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      06-07-2009, 06:03 PM   #50
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If those shavings are in the IC, they are in the combustion chambers - I would scope the engine and see what the pistons and walls look, probably do a leakdown test also to see how much damage has been done to the engine. The turbo(s) are most likely done with the IC looking like that, but how much engine damage has been done internally is more of an issue at this point!
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      06-07-2009, 08:47 PM   #51
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Quote:
Originally Posted by SkySoldier View Post
How would the metal shavings make their way into the oil?
There are oil passages that run along the block for cooling purposes as well as running up into the head as well.
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      06-07-2009, 09:57 PM   #52
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If those shavings are in the IC, they are in the combustion chambers - I would scope the engine and see what the pistons and walls look, probably do a leakdown test also to see how much damage has been done to the engine. The turbo(s) are most likely done with the IC looking like that, but how much engine damage has been done internally is more of an issue at this point!
yup, there is your main issue now....is the engine toast?

if there are metal shavings in the oil pan then yes, there may be some more serious damage.

best of luck
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      06-08-2009, 12:40 AM   #53
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yup, there is your main issue now....is the engine toast?

if there are metal shavings in the oil pan then yes, there may be some more serious damage.

best of luck
Yep, unfortunately that is most likely the case... I would not drive the car until you get it looked at... You don't want to do any more damage to the engine.


Hopefully its not a total led engine.. I wish you luck OP.
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      06-08-2009, 08:56 AM   #54
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Quote:
Originally Posted by roadkillrob View Post
If those shavings are in the IC, they are in the combustion chambers - I would scope the engine and see what the pistons and walls look, probably do a leakdown test also to see how much damage has been done to the engine. The turbo(s) are most likely done with the IC looking like that, but how much engine damage has been done internally is more of an issue at this point!
That + draining the oil is good advice before you go pumping more money into modding.
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      06-08-2009, 02:11 PM   #55
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...
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....
Bad idea man. Definitely don't do that. Not like it will suck in a bird in your garage, but still its damn risky. Second, metal shavings will accumulate over time. Even a mess as big as what you see took time to create. And.. probably only really happens when the engine is under load loading the turbos. What you are really doing is almost like free wheeling a bicycle, even a badly damaged turbo wont really show in your test unless its completely seized. again the crap you are seeing builds up speck by speck so you really wont see anything this way. I would test by looking at crancase and leakdown test as has been suggesteed on here. Definitely don't invest another penny into mods until you know if you have a solid engine. Its not really looking good frowm what I can see so far.
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      06-09-2009, 06:36 PM   #56
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OK so I just ordered a 48ft fiber scope so I can look inside the turbos and inside the engine without having to disassemble half the engine to figure out where those shavings are coming from and how extensive the damage is, hopefully is just one of the turbos and the shavings are coming from the blades due to excessive shaft play...I should know by the end of the week...
In the mean time I took out the intake manifold yesterday to check for shavings and there were none, also pulled out one spark plug and it was clean...so thats good to know...
the good thing is that Im not freaking out to much just a lil bit frustrated because I want to finish this project and lil things like this are slowing me down
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      06-09-2009, 06:41 PM   #57
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Gotta wonder if the blades might be wearing against the compressor housing and that is where the material is coming from.

If that's the case, then the actual blades might look OK on the scope......just depends which material is harder - the compressor housing or the blades themselves.

The material is probably coming from the softer metal.
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      06-09-2009, 06:56 PM   #58
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Quote:
Originally Posted by Ilma View Post
Gotta wonder if the blades might be wearing against the compressor housing and that is where the material is coming from.

If that's the case, then the actual blades might look OK on the scope......just depends which material is harder - the compressor housing or the blades themselves.

The material is probably coming from the softer metal.
the blades will wear long before the housing, they are much much thinner and weaker, they shatter almost.
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      06-09-2009, 06:58 PM   #59
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Quote:
Originally Posted by Ilma View Post
Gotta wonder if the blades might be wearing against the compressor housing and that is where the material is coming from.

If that's the case, then the actual blades might look OK on the scope......just depends which material is harder - the compressor housing or the blades themselves.

The material is probably coming from the softer metal.

I guess we'll find out soon...
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      06-09-2009, 09:48 PM   #60
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I think your engine will be just fine. Those are very fine particles and the FMIC does a good job of acting like a filter, besides the fact that the kind of debris you are showing would go right through the engine without incident. I do think you have at least one blown turbo though.
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      06-11-2009, 07:53 PM   #61
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Ok I finally found out where all the shaving were coming from, and as some of you suspected yes is they were coming from the turbo, the front turbo as a matter of fact... it looks like the nut came off and shattered all the blades...the rear turbo is fine the blades look good...
sorry for the crappy pics but is kind of hard to take pics thru a fibersope.
[IMG]http://i6.photobucket.com/albums/y247/******/Fiberscope/DSCN0957.jpg[/IMG]
[IMG]http://i6.photobucket.com/albums/y247/******/Fiberscope/DSCN0958.jpg[/IMG]
[IMG]http://i6.photobucket.com/albums/y247/******/Fiberscope/DSCN0959.jpg[/IMG]
[IMG]http://i6.photobucket.com/albums/y247/******/Fiberscope/DSCN0960.jpg[/IMG]
[IMG]http://i6.photobucket.com/albums/y247/******/Fiberscope/DSCN0962.jpg[/IMG]
[IMG]http://i6.photobucket.com/albums/y247/******/Fiberscope/DSCN0952.jpg[/IMG]
[IMG]http://i6.photobucket.com/albums/y247/******/Fiberscope/DSCN0956.jpg[/IMG]
[IMG]http://i6.photobucket.com/albums/y247/******/Fiberscope/DSCN0954.jpg[/IMG]
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      06-11-2009, 08:09 PM   #62
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If you replace the Turbo, make sure you replace both I'd really doubt its completely intact either. Those small shaving, the metal dust work their way around the engine out the Turbos too. I mean you had a lot of shavings, I am sure some got past your pistons too scratching the cylinder walls, but probably not enough to cause any real noticeable damage. The turbos, different story. I'd change both of them. Sorry man, I thought your Turbo was SOL, but still it feels bad seeing the reality of it. Anyway, atleast now you are aware of where they are coming from.
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      06-11-2009, 08:19 PM   #63
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Wow. Nice pictures. I just saw my turbo blades yesterday when the downpipes were off and they looked great so far.
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      06-11-2009, 08:21 PM   #64
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I guess is time for new turbos, hopefully I'll get my DP's from Vk around the same time so I can do all of it at one shot...
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      06-11-2009, 08:54 PM   #65
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That sucks, but the pics do look pretty cool.
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      06-11-2009, 08:59 PM   #66
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Great Pics thanks for sharing! I'm hoping you get it fixed quickly.

Quote:
Originally Posted by ****** View Post
Ok I finally found out where all the shaving were coming from, and as some of you suspected yes is they were coming from the turbo, the front turbo as a matter of fact... it looks like the nut came off and shattered all the blades...the rear turbo is fine the blades look good...
sorry for the crappy pics but is kind of hard to take pics thru a fibersope.
[IMG]http://i6.photobucket.com/albums/y247/******/Fiberscope/DSCN0957.jpg[/IMG]
[IMG]http://i6.photobucket.com/albums/y247/******/Fiberscope/DSCN0958.jpg[/IMG]
[IMG]http://i6.photobucket.com/albums/y247/******/Fiberscope/DSCN0959.jpg[/IMG]
[IMG]http://i6.photobucket.com/albums/y247/******/Fiberscope/DSCN0960.jpg[/IMG]
[IMG]http://i6.photobucket.com/albums/y247/******/Fiberscope/DSCN0962.jpg[/IMG]
[IMG]http://i6.photobucket.com/albums/y247/******/Fiberscope/DSCN0952.jpg[/IMG]
[IMG]http://i6.photobucket.com/albums/y247/******/Fiberscope/DSCN0956.jpg[/IMG]
[IMG]http://i6.photobucket.com/albums/y247/******/Fiberscope/DSCN0954.jpg[/IMG]
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