SIB-11-13-07

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SB-10037657-5808
SI B11 13 07
Engine
June 2012
Technical Service
This Service Information bulletin supersedes SI B11 13 07 dated August 2010.
designates changes to this revision
SUBJECT
N54 Engine: 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.
1.
Perform ISTA/D test plan W1214_DI6TLM_ Noticeable symptoms: turbo charger
malfunction. (Path: Function Structure – 05 Non-electrical diagnosis – 01 Engine – 01
Interference noise – Engine noise – Noises at turbo charger – Start Search and follow displayed
test plan).
Note: For models and production rages not described in this document, refer to the applicable test
plans described in the current version of ISTA/D.
2.
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.
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Note: When the ISTA system message displays: Battery voltage only “XX.XX” V. Please connect
charger. Please note the displayed battery voltage reading in the repair order comments section.
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 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.
1. 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.
2.
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.
Note: When the ISTA system message displays: Battery voltage only “XX.XX” V. Please connect
charger. Please note the displayed battery voltage reading in the repair order comments section.
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:
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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/SAV Limited Warranty, and as applicable, any
Federal, State or BMW Emissions Warranty or the BMW Certified Pre-Owned Limited Warranty (only
applies to BMW vehicles that are still within the BMW CPO coverage period but beyond the BMW
New Vehicle/SAV Limited Warranty or Emissions Warranty coverage that applies to the specific
repair).
Please see SI B01 02 11 for “Emissions Warranty Coverage” and refer to the “Glossary of Emission
Coverage” attachment for more information.
Performing Test Plan and Programming/Encoding Vehicle
Defect Code:
11 65 05 39 00
Labor Operation
Labor Allowance
Description
00 00 006
Refer to KSD2
Performing
“vehicle
test” (with vehicle
diagnosis system
– checking faults)
and if necessary, also
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61 21 528
Refer to KSD2
Charging battery
WT
Performing
vehicle diagnosis
– test module.
Refer to KSD2
Programming /
encoding control
unit(s) (not
including CAS)
Refer to KSD2
Programming /
encoding control
unit(s) (with
CAS)
and if necessary, also
61 00 006
and
61 00 710
or
61 00 720
Labor operation code 00 00 006 is a Main labor operation. If you are using a main labor code for another
repair, use the plus code labor operation 00 00 556 instead.
Refer to KSD2 for the corresponding flat rate unit (FRU) allowance. Enter the Chassis Number, which
consists of the last 7 digits of the Vehicle Identification Number (VIN). Click on the “Search” button,
and then enter the applicable flat rate labor operation in the FR code field.
Even though work time labor operation code 61 00 006 ends in “006,” it is not considered a Main labor
operation.
Work time (WT) labor operation 61 00 006 requires an individual punch time.
If a control module fails to program correctly or initializations are required, the additional work must be
claimed with separate labor operations under the defect code listed above, refer to KSD2.
Replacing Both Turbocharger Wastegates Actuators (as outlined above)
Defect Code:
11 65 20 48 00
Labor Operation:
Labor Allowance:
Description:
11 65 548
Refer to KSD2
Removing and
installing or
replacing
both exhaust
turbochargers
and
11 65 580
Refer to KSD2
Adjusting
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vacuum units
and replacing if
necessary
Refer to KSD2 for the corresponding flat rate unit (FRU) allowance. Enter the Chassis Number, which
consists of the last 7 digits of the Vehicle Identification Number (VIN). Click on the “Search” button,
and then enter the applicable flat rate labor operation in the FR code field.
[ Copyright © 2012 BMW of North America, LLC ]
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