Front wastegate rattle

Amizzi · 08-03-2015, 09:08 PM

Hi everyone,
I am fairly new to the forums as I recently purchased a 07 335xi not long ago.
After only a month of ownership @ about 78k on the odometer I developed the dreded wastegate rattle and lucky me it was the front

I've been working on cars most of my life so I figured I would try and tackle this myself .
I just wanted to share a few tools I made up to aid in the adjustment of the wastegate actuator rod.

Now I'm not going to lie, this was an absolute PITA but resolved my rattle for now anyways till I'm ready to replace the turbos .

To turn the locking nut I used a 13mm wrench and welded a 10mm 1/4" drive 12 point socket into the box end of the wrench. Then cut a section down the socket big enough for the rod to fit in . Then I simply slid the tool down till it grabbed the nut.

To turn the rod I used a couple of 8mm and 9mm wrenches that I cut the opened ends off and cut out a small section 4mm wide to turn the rod. I had to make a few bends as there is very little clearance as a lot of you already know.

The amount of slack in the rod was unreal! I can't believe there was as much play as there was! The rod traveled about 1/4" before it began to pull the arm. After I adjusted the rod to the point where it took the slack out I installed e clips and lathered the connection with high heat antisieze to hopefully prolong any more wear .

I know there are a lot of threads on this topic, I just wanted to share what I made to make this job a little easier

Game · 08-03-2015, 09:15 PM

God I hate wastegate rattle. This "DIY" let's pretty complex, but glad it worked out for you.

Real Nice Guy · 08-03-2015, 09:21 PM

Nice work! I have done every mod possible to the rear wastegate but still have some rattle from the front.
Working from under the car, how many other parts were in the way?

Amizzi · 08-03-2015, 09:39 PM

Thanks guys!!!
Ya that rattle sound was making me nuts!!!
I performed all the work from underneath, unfortunately with the xi you need to lower/drop the subframe to in turn remove the downpipes....
Once you have the dp's off you can get your hand in there .
Then all you need is a case of beer and patience

feuer · 08-03-2015, 10:41 PM

Awesome! Ingenuity pays off. Enjoy the reward = rettleless 335i

fun2drive · 08-04-2015, 02:58 PM

While there are many complaints on the rattle your's is the first write up I have seen on someone tackling the adjustment without pulling the turbos's.
Good job!!!!!

924er · 08-04-2015, 03:04 PM

Wg rattle never bothered me

theduker456 · 08-04-2015, 06:27 PM

I believe that I've had this rattle since the spring. I finally went under the hood to look around and the only thing I found that might be making the noise was the waste gate actuator rod assembly. I assume that I was looking at the front one since I only saw one.

Is this covered by the extended waste gate warranty?

Mine resonates and rattles at about 900 rpm under light acceleration in 1st and 2nd gear. Does that sound like the same noise that any of you have heard?

theduker456 · 08-04-2015, 06:50 PM

Did a bit more research - I was wiggling the REAR waste gate actuator rod. Does anyone have the link to the extended warranty?

feuer · 08-04-2015, 08:00 PM

Quote:

Originally Posted by fun2drive

While there are many complaints on the rattle your's is the first write up I have seen on someone tackling the adjustment without pulling the turbos's.
Good job!!!!!

I just did one last Saturday, stubby 10mm and 4mm home made wrench out of 30mm long piece of metal is what I used.
Turbo #1 is extremely difficult. Turbo #2 is easy.
There are a lot of threads on the issue going few years back.
However, this is a first with description on the home made tools!
I admire the ingenuity here!

feuer · 08-04-2015, 08:05 PM

Quote:

Originally Posted by 924er

Wg rattle never bothered me

Didn't bother me either until it started causing limp modes.
Code 30ff an 3100
Mine got replaced under warranty.
I work part time in a shop so last weekend I gave it a go on customers e92.
Went well, although a lot of time consuming. Especially turbo #1
The vacuum hoses are difficult too.
On this car they were clued onto the wastegate due to heat I guess.

misterjim · 08-04-2015, 08:25 PM

Some questions on an old issue: What exactly causes the play in the wastegate actuator rod in the first place? Is it a wear item? Is it 'fixed' with newer version turbos?

feuer · 08-04-2015, 08:45 PM

Quote:

Originally Posted by misterjim

Some questions on an old issue: What exactly causes the play in the wastegate actuator rod in the first place? Is it a wear item? Is it 'fixed' with newer version turbos?

The rattle is caused by combination of things but primarily due to the lid mounted on the wastegate arm becoming loose itself so it rattles when is not closed.
Then not sufficient vacuum to force the lid fully closed.
Lastly weaken actuator.
It is not "fixed" even with the new turbos.
My car had the updated turbos with different shaft installed at 30k
They started failing again at 70k

Amizzi · 08-04-2015, 10:01 PM

Thanks for the complements guys I really appreciate it !
This issue in my opinion is due to poor quality components and material! I've been working with turbo diesels for approximately 12 years now and all of which use the same sort of design in regards to the turbos.Some of the vehicles I have worked with have 500,000km + with no wear at all!

The wear that I found was in the connection from the actuator rod to the arm which had become oval allowing slack. I also had play in the actual wastegate arm going into the housing.

Here is a video I took showing the play in the components, please excuse my speech in the video as I was at the point where I had a few too many beers and had become a bit delirious with this job LOL.
This is just to give you a better visual and understanding of what's going on down there if you have never had it apart before.

AWDBooSTIn90 · 08-06-2015, 03:36 PM

^video is set to private. Couldnt watch.

Amizzi · 08-06-2015, 09:00 PM

Quote:

Originally Posted by AWDBooSTIn90

^video is set to private. Couldnt watch.

Sorry my bad ! Should work now .

AWDBooSTIn90 · 08-06-2015, 09:14 PM

its such a shame that the stock turbos wastegate shafts and flappers are so badly designed. the rattle is very annoying to me. theres nothing wrong with the turbos themselves as far as oil burning or wear, but the dam rattle is enough for me to want to change them/upgrade them.

However, for me right now and 95% of others on the forum, the stock turbo's power limit is plenty. I can have plenty of fun as a street car on FBO and E85 blends on stock turbos.

08-03-2015, 09:08 PM	#1
Amizzi Private 22 Rep 99 Posts Drives: 2007 BMW 335xi Join Date: Jun 2015 Location: Woodbridge Ont iTrader: (0)	Front wastegate rattle - Tools to aid in adjustment Hi everyone, I am fairly new to the forums as I recently purchased a 07 335xi not long ago. After only a month of ownership @ about 78k on the odometer I developed the dreded wastegate rattle and lucky me it was the front I've been working on cars most of my life so I figured I would try and tackle this myself . I just wanted to share a few tools I made up to aid in the adjustment of the wastegate actuator rod. Now I'm not going to lie, this was an absolute PITA but resolved my rattle for now anyways till I'm ready to replace the turbos . To turn the locking nut I used a 13mm wrench and welded a 10mm 1/4" drive 12 point socket into the box end of the wrench. Then cut a section down the socket big enough for the rod to fit in . Then I simply slid the tool down till it grabbed the nut. To turn the rod I used a couple of 8mm and 9mm wrenches that I cut the opened ends off and cut out a small section 4mm wide to turn the rod. I had to make a few bends as there is very little clearance as a lot of you already know. The amount of slack in the rod was unreal! I can't believe there was as much play as there was! The rod traveled about 1/4" before it began to pull the arm. After I adjusted the rod to the point where it took the slack out I installed e clips and lathered the connection with high heat antisieze to hopefully prolong any more wear . I know there are a lot of threads on this topic, I just wanted to share what I made to make this job a little easier Attached Images
	Appreciate 3 Tweet Quote

08-03-2015, 09:15 PM	#2
Game ------ 7406 Rep 10,215 Posts Drives: G87 M2 (sold) Join Date: Aug 2010 Location: Chicago'ish iTrader: (25)	God I hate wastegate rattle. This "DIY" let's pretty complex, but glad it worked out for you. __________________
	Appreciate 0 Quote

08-03-2015, 09:21 PM	#3
Real Nice Guy . 31 Rep 370 Posts Drives: 2008 e90 M3 Join Date: Nov 2013 Location: NJ iTrader: (4)	Nice work! I have done every mod possible to the rear wastegate but still have some rattle from the front. Working from under the car, how many other parts were in the way?
	Appreciate 0 Quote

08-03-2015, 09:39 PM	#4
Amizzi Private 22 Rep 99 Posts Drives: 2007 BMW 335xi Join Date: Jun 2015 Location: Woodbridge Ont iTrader: (0)	Thanks guys!!! Ya that rattle sound was making me nuts!!! I performed all the work from underneath, unfortunately with the xi you need to lower/drop the subframe to in turn remove the downpipes.... Once you have the dp's off you can get your hand in there . Then all you need is a case of beer and patience
	Appreciate 0 Quote

08-03-2015, 10:41 PM	#5
feuer Major General 4276 Rep 9,206 Posts Drives: wife crazy! Join Date: Apr 2015 Location: Chicago, IL iTrader: (5)	Awesome! Ingenuity pays off. Enjoy the reward = rettleless 335i
	Appreciate 0 Quote

08-04-2015, 02:58 PM	#6
fun2drive BMWCCA 149159 38 Rep 847 Posts Drives: 13 128i Vert/ 14 JGC Diesel Join Date: Jul 2006 Location: Florida Panhandle iTrader: (1)	While there are many complaints on the rattle your's is the first write up I have seen on someone tackling the adjustment without pulling the turbos's. Good job!!!!!
	Appreciate 0 Quote

08-04-2015, 03:04 PM	#7
924er Colonel 352 Rep 2,050 Posts Drives: e92 335i '10 Join Date: Feb 2014 Location: Socal iTrader: (0)	Wg rattle never bothered me __________________ '10 e92 N54 DCI intakes, ER chargepipe, TIAL BOV, VRSF 5in FMIC, BMS Downpipes COBB e30
	Appreciate 0 Quote

08-04-2015, 06:27 PM	#8
theduker456 Private 19 Rep 97 Posts Drives: 2009 335i Xdrive Join Date: Mar 2012 Location: Berwyn, Pa USA iTrader: (1)	I believe that I've had this rattle since the spring. I finally went under the hood to look around and the only thing I found that might be making the noise was the waste gate actuator rod assembly. I assume that I was looking at the front one since I only saw one. Is this covered by the extended waste gate warranty? Mine resonates and rattles at about 900 rpm under light acceleration in 1st and 2nd gear. Does that sound like the same noise that any of you have heard?
	Appreciate 0 Quote

08-04-2015, 06:50 PM	#9
theduker456 Private 19 Rep 97 Posts Drives: 2009 335i Xdrive Join Date: Mar 2012 Location: Berwyn, Pa USA iTrader: (1)	Did a bit more research - I was wiggling the REAR waste gate actuator rod. Does anyone have the link to the extended warranty?
	Appreciate 0 Quote

08-04-2015, 08:25 PM	#12
misterjim Private First Class 35 Rep 191 Posts Drives: 2008 e93 335i Join Date: Apr 2007 Location: Rochester, NY iTrader: (0)	Some questions on an old issue: What exactly causes the play in the wastegate actuator rod in the first place? Is it a wear item? Is it 'fixed' with newer version turbos?
	Appreciate 0 Quote

08-04-2015, 10:01 PM	#14
Amizzi Private 22 Rep 99 Posts Drives: 2007 BMW 335xi Join Date: Jun 2015 Location: Woodbridge Ont iTrader: (0)	Thanks for the complements guys I really appreciate it ! This issue in my opinion is due to poor quality components and material! I've been working with turbo diesels for approximately 12 years now and all of which use the same sort of design in regards to the turbos.Some of the vehicles I have worked with have 500,000km + with no wear at all! The wear that I found was in the connection from the actuator rod to the arm which had become oval allowing slack. I also had play in the actual wastegate arm going into the housing. Here is a video I took showing the play in the components, please excuse my speech in the video as I was at the point where I had a few too many beers and had become a bit delirious with this job LOL. This is just to give you a better visual and understanding of what's going on down there if you have never had it apart before.
	Appreciate 0 Quote

08-06-2015, 03:36 PM	#15
AWDBooSTIn90 Nomore 149 Rep 793 Posts Drives: 335i Coupe 6MT N54 Join Date: Feb 2014 Location: Long Island iTrader: (1)	^video is set to private. Couldnt watch.
	Appreciate 0 Quote

08-06-2015, 09:14 PM	#17
AWDBooSTIn90 Nomore 149 Rep 793 Posts Drives: 335i Coupe 6MT N54 Join Date: Feb 2014 Location: Long Island iTrader: (1)	its such a shame that the stock turbos wastegate shafts and flappers are so badly designed. the rattle is very annoying to me. theres nothing wrong with the turbos themselves as far as oil burning or wear, but the dam rattle is enough for me to want to change them/upgrade them. However, for me right now and 95% of others on the forum, the stock turbo's power limit is plenty. I can have plenty of fun as a street car on FBO and E85 blends on stock turbos.
	Appreciate 0 Quote