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Go Back   Bimmerfest - BMW Forums > BMW Model Discussions > 3 Series / 4 Series > E90/E91/E92/E93 (2006 - 2013)

E90/E91/E92/E93 (2006 - 2013)
The E9X is the 4th evolution of the BMW 3 series including a highly tuned twin turbo 335i variant pushing out 300hp and 300 ft. lbs. of torque. BMW continues to show that it sets the bar for true driving performance! -- View the E9X Wiki

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Old 03-27-2014, 02:58 PM
Eurobahn Motorsports Eurobahn Motorsports is offline
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Location: Greensboro, North Carolina
Join Date: Jan 2014
Posts: 29
Mein Auto: BMW's BMW in Greensboro
2006 e90 335i N54 Turbo/Headgasket tear-down and replacement

We have recently begun to replace both turbines along with the head-gasket on a 2006 335i with just over 100,000 miles on the N54 engine powering this vehicle. The car was brought in due to a rattle coming from the engine compartment.

It was found that this rattle came from the actuating mechanism of the internal waste gates on both turbos. With the engine dropped out of the vehicle, and the turbos removed from the exhaust side of the engine, it became clear that the head-gasket was also beginning to leak.

Both of these issues are pretty detrimental considering the vehicles age and mileage, but nevertheless, the service has begun.

This will be part one of the our tear-down article, with images of the disasembly process, along with the new turbines to be used on the vehicle. All pictures can be found below.

As we reassemble the engine, part two of our tear-down will follow
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Old 03-27-2014, 06:23 PM
alpinweiss alpinweiss is offline
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Location: Nuevo MÚxico
Join Date: Sep 2009
Posts: 1,509
Mein Auto: E46, E83, E90 (all MT)
Thank you for the great photos! Something tells me this is not going to be cheap.

We will definitely appreciate updates, as this engine gets rebuilt.

Is it possible this is a 2007 model? I thought that was when the E90 335 models began.

E46, E83, E90 (all with three pedals)
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Old 03-28-2014, 04:58 AM
roadkillrob roadkillrob is offline
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Location: Boston
Join Date: Aug 2006
Posts: 2,376
Mein Auto: 325CIC, 335CIC
BMW did not make a 2006 model year 335i in the US - it has to be a 2007, it may have been manufactured in the last 3 months of 2006 but would definitely be a 2007 model - the 2006 model E90 was a 330i or 325i.
2008 335i Vert Montego/Saddle/Grey Poplar
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Old 03-28-2014, 05:41 AM
hondo402000 hondo402000 is offline
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Location: Charlotte, NC
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Posts: 1,642
Mein Auto: 2007-335 HTC
are they doing anything to the lower end? Check the Crankshaft? new bearings? Oil pump, check pistons, hone cylinders and new rings,

if its down that far why not have everything replaced and rebuilt?
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Old 03-28-2014, 07:22 AM
fdriller9 fdriller9 is online now
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Location: NJ/Philly
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Posts: 2,803
Mein Auto: '06 AW 330xi
Wastegate rattle is quite common on the N54.

I wonder if the engine was overheated as one point or if the head gasket is just failing. Any sheared off head bolts? Common on N52 but I've heard of one or two cases with N54s.

Any idea if this engine was tuned?

How was the carbon build up on the intake ports?

Thanks for posting pictures!

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Last edited by fdriller9; 03-28-2014 at 07:23 AM.
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Old 03-28-2014, 06:06 PM
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fun2drive fun2drive is offline
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Location: Panhandle of Florida
Join Date: Nov 2005
Posts: 2,610
Mein Auto: 335 vert//M3/4/ 13Outback
For 100K miles the pistons look in excellent shape. Very little carbon build up.
Looking forward to the metamorphous to single turbo...
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Old 03-28-2014, 07:53 PM
sptt144 sptt144 is offline
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Location: Orange County, Ca.
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Mein Auto: 2009 335i
Based on the two head jobs I have done myself, that doesn't look very good from a maintenance perspective (could be the photos). I've seen cleaner heads from 200K Mercedes Engines. That's why I change my oil every 3-7K even though it's 15K recommended. New turbos look "refreshed"!
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Old Today, 02:47 AM
DCOOK0 DCOOK0 is offline
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Location: APO
Join Date: Feb 2014
Posts: 2
Mein Auto: 07 E90 335xi
Any updates?
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100000 miles, 335i, headgasket, internal, leak, n54, turbo, wastegate

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