[bigdaddycane]

I had my car at the dealer this week for the HPFP and Injector recall as well as what I thought was the driver-side muffler replacement (due to muffler valve going bad).

They just called me back and told me the rattle is the waste gate actuators needing to be replace. I have dealt with the rattle for a long time because I was convinced it was the muffler valve as the sound was solely in driver-side muffler. The sound is resonating all the way down to the muffler; literally NO sound up near the engine. Engine harmonics at work.

The main reason I posted this is because the CPO extended warranty does NOT cover the waste gate actuator replacement; this was news to me. I thought because I had the CPO warranty that I was covered on most issues. Evidently, certain parts on the exhaust of this car are NOT covered by the CPO Extended Warranty.

My car JUST turned 50K and the appointment was made prior to crossing that mark so they will cover the replacement for me.

Those with 07 and 08 135s and 335s should really make sure they aren't experiencing the waste gate rattle issue or get checked before the 4 year 50K warranty is up.

[fisherbln]

Even more glad I purchased an aftermarket warranty instead of the BMW warranty. My turbos were already replaced by my aftermarket warranty... $4200!

[bigdaddycane]

^ Turbos are covered by the BMW CPO Extended Warranty, Waste Gate Actuators are NOT....

[anerbe]

If the CPO does not cover the turbo assembly, it's a big waste of money. It's a vital part of the engine - it's not for the functionality of the exhaust

[bigdaddycane]

The turbos themselves are covered.....some components around them are NOT.

Guys, this is the actuators NOT the waste gates themselves.

I'm going to ask the dealer for a breakout of exhaust components that are not covered.

[anerbe]

Originally Posted by bigdaddycane

The turbos themselves are covered.....some components around them are NOT.

wow, i consider wastegates part of the turbo (so are turbines, bearings, etc....) - being part of the exhaust seems very shady considering to fix wastegate rattling issues, they were replacing the turbos.

[BobS]

Originally Posted by fisherbln

Even more glad I purchased an aftermarket warranty instead of the BMW warranty. My turbos were already replaced by my aftermarket warranty... $4200!

How much did it cost you for the aftermarket warranty? I assume because its aftermarket, they don't really beat you up to bad on mods? Or even look for it if you take off the mods?

I may go this route.

[turbo2nr]

is their a list some where what EXACTLY is and isnt covered under cpo?

im bringing my car in on tues for a check it has 51k, i dont want to be jerked around.

also for the recalls when i bring in the car i just tell them i would like these recalls done? or do i need to bring in some kind of proof that my car needs them?

thanks sorry for thread jacking

[bigdaddycane]

also for the recalls when i bring in the car i just tell them i would like these recalls done? or do i need to bring in some kind of proof that my car needs them?

You should have gotten a letter in the mail telling of the HPFP recall.

I made the appointment for several things as well as the HPFP and asked if they would check the injectors for that recall as well. No issues, they are getting so many 135s and 335s each week they're expecting it.

[turbo2nr]

i bought the car pre-owned so i am not the original owner so i wouldnt have the recall letters...

[mase]

Originally Posted by turbo2nr

i bought the car pre-owned so i am not the original owner so i wouldnt have the recall letters...

you should still get the letters if you bought the car pre-owned... i did.

[bigdaddycane]

^ +1 I did as well...

I think because you JUST bought it it will take a little bit to get sent out to you.

[turbo2nr]

cool thanks for the info i have already updated my info with bmw usa so i guess it will come in the mail.

[gboop]

Originally Posted by bigdaddycane

The turbos themselves are covered.....some components around them are NOT.

Guys, this is the actuators NOT the waste gates themselves.
I'm going to ask the dealer for a breakout of exhaust components that are not covered.

How much did they quote you for the fix?

[bigdaddycane]

they didn't give me a quote since it was covered (barely).

I'll ask them this afternoon when I pick it up.

UPDATE: I asked what the damage would have been (if I had to pay) and the best I could get out of the SA was ~$800 for parts and 10 or 11 hours of labor.

[ChanhassenBMW]

I have a 2007 335xi and this past weekend kept getting the EML (engine light half lite up yellow) and couldn't accelerate past ~2k rpm. Brought it into the dealer and found out about the HPFP you are talking about. I so happened to ask about this "rattling" noise that I too have gotten used to and now they are replacing the turbos! I get the car back on Thursday so I will let you all know what they did and if it solved all the problems. I'm glad I'm still at 40k miles and under coverage. The service tech said it would have cost ~$6,000 for everything he is doing for me.

[bigdaddycane]

nice....good luck with the new turbos!

[335si]

I have had the software update and the "new" wastegate actuators installed by the dealer under the factory warranty only to continue to have the rattle. Car is at the dealer again waiting on new turbos as we speak. I hope this solves my rattling problem once and for all.

I am not sure what the CPO covers....but it seems very limited...

[ChanhassenBMW]

Just got my car back! New fuel pump works great. And the new turbos are super quiet! No rattling noises at all. The dealership first updated the software but that didn't fix the problem. So they got approval to replace the turbos. Once out they checked the waste gates and there was a lot of slop in them. Hopefully it doesn't happen again! FYI to everyone with this issue and you are under warranty - get your turbos replaced! Also, I'm not noticing any LAG with the new system. Although I'm not as sharp on cars as some of you are, I can't notice any changes.

[bigdaddycane]

^ sweet! now it's time to mod it!!!

[GiRtHyN55]

The actuators and the turbos are covered. See SIB below :

designates changes to this revision

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.

Note 2: In the case where Progman requires the replacement of control modules or additional programming because certain control modules failed to program correctly, print out the Measures Plan and Status Report/Final Report as described in the Progman programming procedure (B09 05 01). Attach these reports to the RO in the vehicle file. This additional work should be claimed under the defect code listed in this bulletin using the labor operation and labor allowance from the KSD.

Labor Operation:
Labor Allowance:
Description:

*11 65 048
Refer to KSD based on model
Removing and installing or replacing

both exhaust turbochargers


+11 65 580
Refer to KSD based on model
Adjusting vacuum units and replacing

if necessary

[bigdaddycane]

GiRtHyN55,

Is this from the Regular Warranty or the CPO/Extended Warranty?