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"winning is endurance" |
BMW |
MERCEDES |
PORSCHE |
FERRARI |
MINI |
Figure 13 shows a broken DISA valve. The plastic pivot that the flap rotates on fatigues over time, and snaps. The result is a rattling sound from the intake manifold, and reduction in engine power. Also, the diaphram can leak vacuum, causing additional issues to the fuel trim (and check engine light). |
Figure 13, BMW DISA Valve. |
Figure 14a, BMW Valvetronic Sensor. |
Figure 14a shows a leaking BMW Valvetronic sensor. The oil in the electrical connector causes electrical shorts, resulting in engine engine stalling, rough running, and service engine soon warning light. Figure 14b displays the Valvetronic sensor removed from the engine. Figure 14c shows the location of Vlavetronic sensor in the engine. See the red-circled part. |
Figure 14b, BMW Valvetronic Sensor. |
Figure 14c, BMW Valvetronic Sensor. |
Figure 15, Faulty Air Mass Sensor Insert. |
Figure 16, Damaged Trunk Wiring. |
Figure 15 displays a faulty air mass meter insert. The air mass meter allows the engine management module to deliver the correct air/fuel mixture to the engine. When a air mass meter goes faulty, a check engine warning (or service engine soon) will display, poor engine performance, and poor fuel economy. |
Figure 16 shows some damaged wiring (circled in red) in a trunk. The wiring gets damaged in two common ways: 1) the pivoting action of the trunk lid can fatigue the wiring, causing one or more wires to break. 2) body shops typically rush through the tedious task of proper routing of wiring (insurance companies generally do not like to pay for additional time to address details like proper routing of wires). Incorrect routing of the wiring can lead to pinched of chafed wires. The wiring in the photo was damaged from being pinched by the trunk spring. This vehicle had work done at a body from a rear end collision. The body shop technician routed the wiring too close to the trunk spring. At some point the wiring managed to get caught up in the spring, severing some of the wires. |
Figure 17, Incorrect pollen/cabin air filters. |
Figure 17 shows incorrect pollen/cabin air filters (circled in red). The customer or an unknowledgeable shop installed aftermarket engine air filters in the pollen filter housings. These ill-fitting filters are not filtering the air. The air is just flowing around the filter, and straight into the cabin. The customer did not want to have our technician install the proper pollen filters at this time. Poor quality past servicing, and ignoring present issues is the biggest reason why this vehicle is in such poor condition. |
Figure 18, Seat Occupency Sensor. |
Figure 18 shows a faulty seat occupency sensor. A faulty seat sensor will cause a SRS system dash warning indicator to come on. Replacing one of these seat sensors typically involves partially removing the seat bottom upholstery. The seat sensor damaged commonly results from concentrating weight onto a small area on the seat. For example, putting one's weight on the seat with their knee can damaged the wires that make up the sensor grid. |
Figure 19 shows a leaking Porsche 997 Turbo rear wing hydraulic system leak. In most cases, the hydraulic lines to the pump are found loose, resulting in sticky hydraulic fluid running down the back bumper. Obtaining proper torque on the banjo bolts are tricky due to the opening on the bolt needing to be inline with the tube on the banjo fitting. |
Figure 19, Porsche 997 Turbo Wing Hydraulics. |
Figure 20 shows three different oil drain bolts that we commonly find damaged from inferior servicing. Subject 'A' is a BMW engine oil drain bolt that was overtorqued by a careless past technicain technician. When our technician simply placed a wrench on the bolt, the head of the bolt fell off, spilling oil out of the threaded portion that was still in oil pan (most late model BMW engine oil pan drain plugs are hollow in their threaded section). Subject 'B' is a BMW oil filter housing drain plug with it's inner hex stripped out from another past careless technician. The bolt hex likely stripped due to overtorquing or an incorrect tool was used. Subject 'C' is a Porsche engine oil drain bolt that was found stripped in a similar manner as Subject 'B'. |
Figure 20, Damaged Drain Bolts. |
The following images display the results of rodent damaged wiring in the center of the dash (climate control wiring chewed through). Rodent droppings were found around the damaged wiring. The entire dash and center console had to be removed in order to repair 25 damaged wires. The image below shows a close-up of the damaged wiring. |
The image above displays an opening where the rodent(s) gained access to the interior of the vehicle. The image to the left displays the solution: blocking the hole with two large metal washers held securely together with a nut and bolt - should be resistant to rodent chewing. |
Figure 25, Porsche IMS Bearing Failure. * Models Effected: All model years 1997-2008 Boxster, Cayman, and 911 models can suffer from IMS failures, with exception of Turbo, GT2, or GT3 models. |
Figure 25 shows an IMS bearing (Intermediate Shaft Bearing) on a water-cooled era Porsche 911 (996). Failure of this bearing leads to drastically skewed cam timing, and major engine damage as a result. Generally, in the early stages of bearing failure the bearing may leak engine oil onto the ground, and metallic flakes can be found in the oil filter. At this point, the days are numbered before engine damage results. In order to replace the IMS bearing, the transaxle must be removed along with the clutch assembly. This makes the cost of replacing the bearing expensive, especially if the clutch assembly and flywheel are in need of replacement. However, this is certainly cheaper than replacing the whole engine. Additionally, the IMS bearing that we install has a much better construction than the factory Porsche bearing, making this repair a one-time repair. |
Figure 22 shows a BMW Mechatronic seal. The Mechatronic seal resides above the valve body and the transmission housing. Over time, the seal gets pulled in disrupting fluid flow, resulting in irregular gear shifting. We replace the Mechatronic seal on all of our transmission services on 2002 and newer 7 series, 2006 and newer 3 series, 2005 and newer V8 X5, 2004 and newer 6 series, 1 series, 2004 and newer 545i, 2006 and newer 5 series., X6 series, 2006 and newer Z4. |
Figure 22, BMW Mechatronic Seal. |
Figure 23, Mercedes ABC Valve Block Seal. |
Figure 23 shows a Mercedes ABC (Active Body Control) seal from the centrally located valve block. As you can see, the seal is damaged, and was leaking suspension hydraulic fluid. Enough fluid escaped to allow the vehicle to lower down to a point where the vehicle was not safe to drive. In many cases, the front tires contact the fenders while turning, causing fender damage. When this much fluid escapes the system, the suspension pump is often damaged in the process. |
Figure 24, Porsche (99-05 911) water hose fitting. |
Figure 24 shows a broken water hose fitting from 99-05 911. The fitting is constructed out of plastic, and eventually breaks from age/heat/fatigue, resulting in rapid coolant loss, and possible engine damage if quick action is not taken in shutting down the engine. |
Figure 25b, Original IMS Bearing circled in red. |
Figure 25c, New IMS Bearing Installed. |
Figure 21, BMW Solenoid for Vanos System. |
Figure 21 shows a BMW Vanos solenoid for 2006 and newer 6 cylinder engines. There are two of these solenoids next to each other. During engine repairs, its very easy to get the connectors mixed up and cross-connected, because the connectors are identical, and even their wiring lengths are similar. If the solenoids are cross connected, the results will be a Service Engine Soon warning, and irregular engine performance due to the cam sensor correlation discrepencies being picked up by the DME. |
Figure 26, Mercedes SL500 Door Handle. |
Figure 26 shows a faulty drivers door handle from a Mercedes SL500 230 chassis series. Wear and age causes the internal electronics of the door handle to fail. The door handle on the 230 chassis series (2003 and newer) can be replaced without removal of the inside door panel, so the replacement can be performed in a relatively short amount of time. |
Figure 27, 2009 Mini Cooper 'S' R55 High Pressure Fuel Pump and Cam Chain Tensioner. |
Figure 27 shows a worn high pressure fuel pump and worn can chain tensioner. The updated cam chain tensioner from Mini is longer to further prevent the possibility of cam chain rattle. The high pressure fuel pump is also the source of rattling sounds as they wear. Although not in the photo, the vacuum pump can be another source of rattling noises as well. |
Figure 28, Mini Cooper Fuel Filter and Seals. |
Figure 28 shows a 100,000 mile fuel filter from a 2004 Mini Cooper 'S'. We recommend the replacement of fuel filters every 30,000 mles. Restricted fuel filters cause the fuel pump to work harder, leading to the eventual failure of the pump. Note: a new fuel filter is white. The one in the photo is nearly black due to having 100,000 miles of use on it - very bad for the pump. |
Figure 29, Mercedes CLS55 AMG fuel pump relay. |
Figure 29 shows a melted fuel pump relay and connector from a Mercedes CLS55 AMG. On this series of Mercedes, there is one relay for both (2) fuel pumps on the AMG model, yet Mercedes kept the single relay configuration of the standard single pump model. With only one relay carrying the load of two fuel pumps, it doesn't take much for any additional amperage to cause excessive heat to build up, and melt the relay and connector. |
Figure 30b, BMW E90 Fuel tank vent valve hose. |
Figure 30a, BMW E90 Fuel tank vent valve. |
Figure 30a and 30b shows a hole worn through a fuel tank vent valve. It's very important that these hard plastic hoses do not rub on any nearby components. The EVAP system monitor on late model BMWs is highly sensitive. |
Figure 31, Mercedes Cam Adjuster Magnet |
Figure 31 shows a pair of late model 2006+ Mercedes cam adjuster magnets. This is a common source of activating the service engine soon warning indicator. Over time, the cam adjuster magnet will leak oil into the electrical connector, causing shorts in the electrical signal to the DME module. |
Figure 32, BMW E90 Windshield Wiper Relay. |
Figure 32 shows a faulty windshield wiper relay from an E90 chassis 3 series BMW. As the relay goes faulty, the early symptoms will be intermittent function of the wiper blades, and eventually the wiper blades will cease to function all together. |
Figure 33, Sludge build up in the valve cover breather tube. |
Figure 33 shows sludge build up in a valve cover breather tube (circled in red). The most common causes of sludge build up in an engine is from a combination of poor quality oil and infrequent oil and filter changes. The example in the photo is a Mercedes valve cover from a 2000 C280 with 140,000 miles, but the sludge condition will affect other engines in the same way. Clogged breather tubes will cause excess crankcase pressure, resulting in oil leaks, and irregular performance. To avoid sludge build up, simply change the engine oil and filter with high quality oil and a factory oil filter from when the engine is new. If you already have sludge build up, you can reduce a bit of the sludge by doing frequent oil and filter changes (every 5000 miles or less). |