[Streetluger06]

My turbo went out and I decided to replace both of mine. I didn't have warranty so I picked up a low mileage used set and a bently manual ~$500 total and now my car is running like a raped ape again. The swap isn't that hard but very tedious if you don't have a lift.

[bigdaddycane]

Your dealer needs to cover this work....they know full well these cars have had turbo issues from the beginning. Am I missing something, or has your basic warranty out now? Do you have an extended warranty?

Show this to your SA

SUBJECT
N54 Distinct Clanking Noise from Turbocharger Area


MODEL
E90, E92 and E93 (3 Series) 335i and 335xi

E60 and E61 (5 Series) 535i and 535xi

All with N54 engine from the start of production up to March 2008 production


SITUATION
The customer complains of a metallic noise from the exhaust system near the engine or turbocharger area. This noise is described as a clanking noise, occurring up to six or seven times in a row during a deceleration from approximately 3,500 RPM; or during a heavy application of the accelerator without a drive gear being engaged.

Complaints received regarding a slight rattle from this area under steady acceleration in the 2,000 RPM to 4,000 RPM range are due to the rotating waste gate valve face; this is a characteristic of the mechanical waste gate. The rotating waste gate valve face is necessary to ensure proper sealing. This slight rattle noise is considered normal operation of the mechanical waste gate valve. No repair should be attempted for this type of rattling complaint.

CAUSE
The wastegate valve does not completely close due to the mechanical tolerances of the wastegate actuator. This results in the wastegate valve repeatedly clanking against its seating surface.

PROCEDURE
Vehicles produced from May 2006 up to September 2007

Do not replace the turbocharger or adjust the existing wastegate actuator control rod.

Perform ISID Test Plan; Noises at Turbocharger (Path: Function Structure – Drive – Mechanism, Noises, Leaks – Noises – Engine Noise – Noises at Turbocharger – Start Search and follow displayed test plan.

The test plan will conclude with an instruction to replace the wastegate actuators; ignore this instruction. Reprogram the DME if the vehicle has not already been programmed to one of the levels described below. Compare the vehicle I-Level to the table below.

Model
Vehicle Data Status

E90, E92, and E93 (335i and 335xi)
E89x-08-03-530 or higher

E60 and E61 (535i and 535xi)
E060-08-03-525 or higher

3. If the vehicle has not achieved one of the levels above, reprogram the vehicle using ISTA/P 2.32.1 or a more recent version.

4. After programming is completed, if the noise is no longer present, take no further action. If the noise is still present, replace both of the turbocharger wastegate actuators in accordance with Repair Instruction RA 11 65 580, Replacing vacuum unit (wastegate) (N54).

Vehicles produced from September 2007 up to March 2008

Do not replace the turbocharger or adjust the existing wastegate actuator control rod.

Perform ISID Test Plan; Noises at Turbocharger (Path: Function Structure – Drive – Mechanism, Noises, Leaks – Noises – Engine Noise – Noises at Turbocharger – Start Search and follow displayed test plan.

The test plan will conclude with an instruction to replace the wastegate actuators; ignore this instruction. Reprogram the DME if the vehicle has not already been programmed to one of the levels described below. Compare the vehicle I-Level to the table below.

Model
Vehicle Data Status

E90, E92, and E93 (335i and 335xi)
E89x-08-03-530 or higher

E60 and E61 (535i and 535xi)
E060-08-03-525 or higher

3. If the vehicle has not already achieved one of the levels above, reprogram the vehicle using ISTA/P 2.32.1 or more recent version.

All 335i/xi and 535i/xi models built from June 2006 up to September 2007

The updated software causes a small amount of increased "turbocharger lag" under certain circumstances and, while not substantial, the lag may be perceptible to the most sensitive BMW drivers. X6, 135i, 3 Series and 5 Series vehicles from March 2008 production onward are not affected. If said "turbocharger lag" is a customer's complaint, then the vehicle's DME software can be retrofitted to the original waste gate operation.

Procedure for vehicles up to September 2007 production:

Using ISTA/P 2.32.1 or a more recent version, select "Conversions", and then select "Wastegate valve conversion". Follow the on-screen prompts to reinstall the original waste gate operation.

After the "Waste gate valve conversion" has been completed, some waste gate-related noise may be detected.

Important Note:

To eliminate the "turbocharger lag" complaint on the vehicles produced from September 2007 up to March 2008 (after programming with Progman versions V29.2 – V32.0), reprogram the complete vehicle, using ISTA/P 2.32.1 or a more recent version.

PARTS INFORMATION
E90, E92, and E93 (3 Series):

Part Number
Description
Quantity

11 65 7 585 745
Actuator Cylinder 1-3
1

11 65 7 585 746
Actuator Cylinder 4-6
1

E60 and E61 (5 Series):

Part Number
Description
Quantity

11 65 7 585 745
Actuator Cylinder 1-3
1

11 65 7 585 747
Actuator Cylinder 4-6
1

WARRANTY INFORMATION
Covered under the terms of the BMW New Vehicle Limited Warranty.

Defect Code:
11 65 05 39 00


Labor Operation:
Labor Allowance:
Description:

*61 00 811
8 FRU
Programming/encoding control units

Including CAS


*61 00 801
7 FRU
Programming/encoding control units

Not including CAS

*Main Work - use this labor operation number when this is the only repair being performed, or if this is the main repair when performed along with other repairs at the same time. If this is not the main repair, refer to KSD for the associated (+) labor operation code.

Note 1: Should the vehicle be affected at the same time by another repair in which programming of control units is also required, programming may be claimed only once.

[Bakeme521]

If I were you I would buy used turbos and have an independent shop install them. If you don't want go used buy them from tischner and bring them to and independent shop.

[Jrl8d]

Originally Posted by bigdaddycane

Your dealer needs to cover this work....they know full well these cars have had turbo issues from the beginning. Am I missing something, or has your basic warranty out now? Do you have an extended warranty?

My basic warranty ended like 4-5 months ago and I do not have an extended warranty. Are you telling me that they should cover it even though I am out of warranty? Thanks for the post btw!

[bigdaddycane]

Are you telling me that they should cover it even though I am out of warranty? Thanks for the post btw!

I'm not saying it will work, but given the low mileage of your car, the fact that the warranty just ran out and the known problem of the N54 turbos, I would bug them and BMW NA to see if they will fix it at their cost. Try another dealer if you have to, but writing a letter to BMW NA might go a long way.

I hope it works out for you....

[Jrl8d]

Originally Posted by Bakeme521

If I were you I would buy used turbos and have an independent shop install them. If you don't want go used buy them from tischner and bring them to and independent shop.

I will check with BMW of Richmond about which parts they are saying I need and then check on that website to check out some costs.

[Evan@Tischer]

Originally Posted by Jrl8d

Are these the newer style turbos that vase refered to, or the same exact version that my car had when it was built? I would much prefer to have the newer version ones that arent complete pieces of crap.

Newest version available...

[Jrl8d]

Originally Posted by Evan@Tischer

Newest version available...

Thanks for your help! I am going to check with the dealor and ask them which exactly which parts I need so that I can properly look at costs. I also need to find a shop that would do this install...

[vase330]

Originally Posted by Evan@Tischer

Newest version available...

Yes those are the ones I referred to. That's what I got installed like 2 weeks back. Tischer has everything you need, if you decide to go OEM just send them your VIN they'll get you right parts. Thats what I did when I bought 313s spoiler, lip from these guys. No problems.

[Jrl8d]

Originally Posted by vase330

Yes those are the ones I referred to. That's what I got installed like 2 weeks back. Tischer has everything you need, if you decide to go OEM just send them your VIN they'll get you right parts. Thats what I did when I bought 313s spoiler, lip from these guys. No problems.

Good Stuff! Sounds like all I need now is a mechanic who will install the parts.

[Yvette]

keep update us, this will be good reference for whoever having problems after their warranty runs out. Hope everything working all good!

[Paul Stig]

I'm in Taiwan, I also changed 2 turbo p/n 11657593015 last week on my 06 E92 335i. I heard these are after upgrade turbo, it seems like overcome the problems? anyone knows it?
thanks

[MyE92]

For those of your who had your turbos changed by the dealer, did you go back to stock before bringing it in? (Downpipes and exhaust)

[Jrl8d]

Originally Posted by bigdaddycane

Your dealer needs to cover this work....they know full well these cars have had turbo issues from the beginning. Am I missing something, or has your basic warranty out now? Do you have an extended warranty?

Show this to your SA

SUBJECT
N54 Distinct Clanking Noise from Turbocharger Area
...

Note 1: Should the vehicle be affected at the same time by another repair in which programming of control units is also required, programming may be claimed only once.

I showed it to my SA and they said that is the actuator problem that causes the ticking sounds and is not the same thing. thanks for the help though

[mweisdorfer]

The initial 50k warranty is 4 Years from the day it was made or originally sold. The cpo takes it an additional 2 years or to 100k which ever comes first. You should still be under CPO till 2013 and maybe under original warranty pending on the date of sale.

The only sticking point is whether the turbos are covered under CPO. Under original warranty they probably would be with out too much question. However, it is my understanding that the CPO warranty is pretty much the same.

This may be worth having a friend who is a lawyer look it thus before shelling out $4000.00

[Jrl8d]

Originally Posted by mweisdorfer

The initial 50k warranty is 4 Years from the day it was made or originally sold. The cpo takes it an additional 2 years or to 100k which ever comes first. You should still be under CPO till 2013 and maybe under original warranty pending on the date of sale.

The only sticking point is whether the turbos are covered under CPO. Under original warranty they probably would be with out too much question. However, it is my understanding that the CPO warranty is pretty much the same.

This may be worth having a friend who is a lawyer look it thus before shelling out $4000.00

I would agree with you on that one but sadly my car is not certified pre-owned. I bought it private party.

[Ilma]

Originally Posted by mweisdorfer

The initial 50k warranty is 4 Years from the day it was made or originally sold. The cpo takes it an additional 2 years or to 100k which ever comes first. You should still be under CPO till 2013 and maybe under original warranty pending on the date of sale.

The only sticking point is whether the turbos are covered under CPO. Under original warranty they probably would be with out too much question. However, it is my understanding that the CPO warranty is pretty much the same.

This may be worth having a friend who is a lawyer look it thus before shelling out $4000.00

I didn't think Lawyer's had any friends?

[vase330]

They will be your friend while you pay them sure!

[Alex@Helix]

Hey,
Sorry to hear about your turbos. I am surprised that they went without you modifying your car. If you are interested in our set up please let me know. You do not need to modify your car heavily to be able run our turbo set up. Although, since your warranty is finished I wouldnt disagree with you if you wanted to tune it up and make it a little monster. Just saying..

[SeanS54]

I remember reading that turbos are part of the "emissions" warranty because it's on the exhaust manifold next to the cats and therefore should be covered longer than the 4 yr/50K miles...

if not I would just get new turbos from tischer and diy it...

[Paul Stig]

Originally Posted by MyE92

For those of your who had your turbos changed by the dealer, did you go back to stock before bringing it in? (Downpipes and exhaust)

Yes, I bring back the stock turbos, but not downpipes and exhaust...
I dont get your point..... Any thing needs to be careful?

[Jrl8d]

Originally Posted by vase330

They will be your friend while you pay them sure!

Good thing my brother is a lawyer