Wastegate Rattle and Engine Malfunction - Reduced Power

[cd85233]

OK All,

Here is a summary of what happened and how I fixed it.

Had WG rattle and "Reduced Engine..." (caused by 310B) error when trying to pass cars around 60 MPH.

Did a pressure test. Found leak at diver side Intercooler/TB interface.

Fixed leak, still rattle and code using guide here: https://goo.gl/aw4CQ1

Still had the 310B fault. And also got a new code: "Charge air Cooling, energy operation Code: 002EA6."

Took out the turbos. Tightened down the WG so that they shut at 10 PSI. Shimmed the rod/WG interface with some copper to reduce rattling. Also shimmed the WG flap with copper wire and some high temp solder. I would not recommend the second part. probably did nothing but now I have to worry about outgassing/wire coming loose.

Follow this guide to remove turbos: https://goo.gl/bpEu16
*Note that I did not remove the cat pipes. I just messed with the clamps until I could get to them. Do yourself a favor and rotate them in an accessible way for next time when you reassemble.

Put Turbos back in. Worked great the first night. Next day I got misfires on C6.

Swapped C6/C7 coils. Misfire followed.

Put new MAP sensor at the intercooler and got rid of the 002EA6 fault.

Took battery off the night before replacing the coils/plugs in order to reset everything. Needed? Probably not but I got tons of faults and some interesting behavior after I did.

Replaced all coils/plugs for ~200 from rock auto. All OEM.

Took it out for a drive. No codes/misfires. Logged data and Boot Setpoint was solid at 14. Probably the car learning some stuff.

Second drive. Eventually got to 0-100MPH on an open road. Everything worked perfectly.

In the picture below you can see how big of a miss the closed loop was for trying to achieve boost. I wont pretend to know all the different aspects of the pressures/WG but I know controls and that is not a well tuned system. PWM to the WG increases on 2 without much result on pressure. Not sure why it reads ambient pressure instead of abs manifold but that's not important to me. Just look at ambient pressure, it's pretty. This is a ~0-60 run which is when the fault would come up.



Now here is the aftermath of all that I did. From a controls theory standpoint, that looks like a tuned PID.



Hope this helps someone!

[m5james]

Great thread! GF's been driving my car and I noticed a few days ago what sounds like wastegate rattle, which would likely explain why I get 30FF no matter what driving style. I just swapped out stock gutted downpipes for wrapped aftermarket ones...I'm not looking forward to pulling the turbos for the first time :/

For those on this thread who've gone rebuilt, either just wastegate or full turbo...who'd you go with? I can afford Pure but I don't want to. I know someone's got a set at Turbo Labs of America but the jury is still out on overall cost I'm sure still half of Pure) and what exactly is getting done since we've got unique turbos vs the N63/N63TU & S63TU.

[cd85233]

If you took out the downpipes you can take out the turbo no problem. It's part of the instructions.

Consider an oem rebuilt. It's like $350 at bmwdirect.

[m5james]

Sorry, can I bother you for a direct link? Searching Google for "bmwdirect" shows me like 3-4 sites and I'm not sure which is which. After that I need to find S63 ones since I'm guessing they're different then your N63 ones.

[cd85233]

https://www.bmwdirectparts.com

Should be easy enough to find on there. Just enter your VIN.

Also, you're gonna need the the gasket kits.

[Gregmanz]

M5james I went cti turbo, they are a branch of comp turbos. I remember we commented to each other on YouTube how turbo lab wouldn’t respond. Comp turbo was great, kept me updated and did a full rebuild with wastegates, 100k rpm balance and warranty, 980 for the pair.

[frankenm]

I went with s63tu turbos to fix my turbo issues

I’ve been having issues with my turbos for sometime ... seem to last around 100k miles?

[Gregmanz]

I can’t say. Haven’t reached that mileage yet. I pulled them out to notice the c clip fell off so the arm wasn’t connected. It was just resting on top where I couldn’t see. But I wasn’t putting them back in without rebuilding regardless after going through the work

[m5james]

Originally Posted by cd85233

https://www.bmwdirectparts.com

Should be easy enough to find on there. Just enter your VIN.

Also, you're gonna need the the gasket kits.

Thank you, sir.

[m5james]

Originally Posted by Gregmanz

M5james I went cti turbo, they are a branch of comp turbos. I remember we commented to each other on YouTube how turbo lab wouldn’t respond. Comp turbo was great, kept me updated and did a full rebuild with wastegates, 100k rpm balance and warranty, 980 for the pair.

I remember and I'm pretty sure I reached out to them once already, just figured I'd see who else is going through who. I've been texting with a member on her about both of us having continual reduced power and who he's having his rebuilt by.

[m5james]

Originally Posted by frankenm

I went with s63tu turbos to fix my turbo issues

I’ve been having issues with my turbos for sometime ... seem to last around 100k miles?

How did this install go anyways? Oil lines, coolant lines, etc all matched up? I've thought about using them as a base for a rebuild since I've already got a set of ceramic coated S63TU headers. Getting matching turbos means I wouldn't need to get machining done to mate my current S63 turbos to the S63TU headers.

You're having issues with your current turbos or you're saying the stock turbos seem to last about 100k?

[frankenm]

Originally Posted by m5james

How did this install go anyways? Oil lines, coolant lines, etc all matched up? I've thought about using them as a base for a rebuild since I've already got a set of ceramic coated S63TU headers. Getting matching turbos means I wouldn't need to get machining done to mate my current S63 turbos to the S63TU headers.

You're having issues with your current turbos or you're saying the stock turbos seem to last about 100k?

I’m at 110k and my stock turbos need rebuilding

I’ve already acquired f10 m5 headers/turbos set and installing soon ... just getting a few more pieces ...

I’m assuming install is going to be quite fun will take some pics

[protecon]

How does the S63 DME handle exhaust gases from opposite banks?
Your air mass in/O2 readings out will be different.