S55 Intake Charge Pipe Failure

[tom @ eas]

Earlier this week, we had a M3 arrive experiencing limp mode and a significant loss of power. These are typical sounds of the charge pipe coming loose on N43/55 models, resulting in a boost leak. We haven't seen this yet on the S55s, so went in for a closer look to see what was wrong.

The following codes were retrieved:

P00BD: Mass or volume air flow a circuit air flow too high
P00BF: Mass or volume air flow b circuit air flow too high
P11E0:

Closer inspection showed the Cylinder 1-3 Charge Pipe dislodged slightly from it's centering pin and saw that the turbo flange was completely separated from the charge pipe. The S55 Intake Charge Pipes are molded from durable ABS plastic with flanges aligned/bonded (likely UV cured) after molding.

Charge Pipe can be seen as #9 in the diagram:



Below is the failed charge pipe along with its replacement for comparison:



A closer look at the flange area shows a clean area in the 9-10 o'clock positions in which the bonding agent didn't fully coat the plastic flange.



Codes were cleared, new charge pipe was installed and M3 was back on the road in no time. Not sure if we're looking at a possible weak link in the charge system, but should serve as a good reference point if this should happen again.

Feel free to discuss.

[TurboSid]

Interesting. There was someone on the forums who's charge pipe had exploded.

[BMWJ]

This has happened to others as well.

[tom @ eas]

Originally Posted by BMWJ

This has happened to others as well.

Heard of it happening more at the heat exchanger up above, haven't seen a case at the turbo directly. Dealers have been removing the rubber couplers degreasing and roughing the clamp area with sandpaper to get a better bite. Seems to be working.

The turbo end is a much different story.

[TeKiZeRo]

Was the M3 stock or was he/she running higher boost from a tune?

[hellrotm]

Is this a hint into a new product you will carry in the future?

[///M ARMY]

This isn't the only time that this has happened with this motor. There is a charge pipe and intercooler that is coming out. It will be out by bimmerfest.

[tom @ eas]

Originally Posted by BlackJetE90

Is this a hint into a new product you will carry in the future?

We've been looking in this area for quite some time so possibly.

No intention of turning this into a sales thread, just sharing info.

[italy3541]

Looking at the diagram it does not look like there is a Diverter vale or BOV on the car from factory. Is that the case? How does the car release the boost pressure after you let off the throttle?

[8600RPM]

Electronic waste gate

[italy3541]

Originally Posted by 8600RPM

Electronic waste gate

Interesting. SO it uses the waste gate as a dump valve and to regulate boost?

[parky1215]

That M3 with failed charge pipe is mine
After this happened, I heard loud air sucking noise whenever I spool turbo.

Thankfully, I got replacement charge pipe immediately from Tom's M4 so I was able to drive the car back to work.

I am not sure if this will happen to stock M3/4.
I had piggyback running with standard boost file.
I know there are bunch of M3/4 out there that are running with higher boost with no issue so far.
I will eventually replace both intake pipe with stronger aftermarket pipe once someone release such product.

[///M ARMY]

Originally Posted by parky1215

That M3 with failed charge pipe is mine
After this happened, I heard loud air sucking noise whenever I spool turbo.

Thankfully, I got replacement charge pipe immediately from Tom's M4 so I was able to drive the car back to work.

I am not sure if this will happen to stock M3/4.
I had piggyback running with standard boost file.
I know there are bunch of M3/4 out there that are running with higher boost with no issue so far.
I will eventually replace both intake pipe with stronger aftermarket pipe once someone release such product.

which tune are you running?

[tom @ eas]

Originally Posted by ///M ARMY

which tune are you running?

Boost is boost, doesn't matter whether its piggyback or flash.

This is likely contributed to a manufacturing failure, as seen on the broken piece. We'll keep an eye out if this happens as more M3/M4s hit the streets.

[///M ARMY]

Originally Posted by tom @ eas

Boost is boost, doesn't matter whether its piggyback or flash.

This is likely contributed to a manufacturing failure, as seen on the broken piece.

Thanks for the info. Still doesn't answer the question

[M3ANS55]

2k miles on the car and my throttle valve went...200 miles after jb4.... rough idle and cel

[Siciliano611]

Originally Posted by parky1215

That M3 with failed charge pipe is mine
After this happened, I heard loud air sucking noise whenever I spool turbo.

Thankfully, I got replacement charge pipe immediately from Tom's M4 so I was able to drive the car back to work.

I am not sure if this will happen to stock M3/4.
I had piggyback running with standard boost file.
I know there are bunch of M3/4 out there that are running with higher boost with no issue so far.
I will eventually replace both intake pipe with stronger aftermarket pipe once someone release such product.

What production month? I thought this was fixed after about 9/14 or 10/14 builds....

[tom @ eas]

Originally Posted by Siciliano611

What production month? I thought this was fixed after about 9/14 or 10/14 builds....

No parts were replaced in the TSB from what I'm aware of, only cleaned/roughed up and reclamped. Then again, we don't hear many reports of charge pipe failures since.

Originally Posted by M3ANS55

2k miles on the car and my throttle valve went...200 miles after jb4.... rough idle and cel

Did your SA give any reason what was the cause from their point of view?

[CaryTheLabelGuy]

Originally Posted by 8600RPM

Electronic waste gate

Electronic wastegate doesn't have anything to do with a diverter valve.

[CanAutM3]

Originally Posted by CaryTheLabelGuy

Electronic wastegate doesn't have anything to do with a diverter valve.

My understanding is that the S55 is not equipped with an intake "diverter valve" or a "bleed off valve". The prevention of a pressure spike in the intake upon quick throttle liftoff is managed by the ECU and that the waste-gates have a role to play here.

[CanAutM3]

Originally Posted by italy3541

Interesting. SO it uses the waste gate as a dump valve and to regulate boost?

I would rather call the waste-gate a "bypass valve". When open, it allows exhaust gases to bypass the turbine of the turbo hence reducing boost and exhaust backpressure at the same time. It is a much more efficient approach for regulating boost, but more complex from an engine management persective.

As for avoiding the pressure spike upon lift off, my understanding is that it is all managed by the ECU.

[italy3541]

Originally Posted by CanAutM3

I would rather call the waste-gate a "bypass valve". When open, it allows exhaust gases to bypass the turbine of the turbo hence reducing boost and exhaust backpressure at the same time. It is a much more efficient approach for regulating boost, but more complex from an engine management persective.

As for avoiding the pressure spike upon lift off, my understanding is that it is all managed by the ECU.

Makes sense. So im guessing then there is no way to put a BOV on the car.