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Default So This Happened This Morning: Catastrophic Engine Failure In Dramatic Fashion - 03-18-2016, 02:33 PM

For the past month I have been plagued by an occasional misfire on cylinder 5, it happens only at WOT when revs get to or beyond 6,400rpm while in 3rd gear. When my car is running 100% I usually shift around 6,500rpm. The misfire happens about 40% of the time so not super consistent but frequent enough to be annoying. I have swapped plugs, coils, and injectors on #5 and the misfire stays, I had not done it for a while so I reswapped the coil and plug and went out to do some data logging. The car acted normal and misfired 2 out of the 5 runs.

Since converting my E61 from AWD-RWD traction in 2nd is an issue and boost was limited to help contain it, recently I took the limiter off to practice my throttle modulation for putting 2nd gear power to the ground, quite tricky.

On the way home from data-logging there was a wide and open section of road so I dropped the car into 2nd at about 35mph and tried to put all the power down, at the top of 2nd gear there was a bang the car instantly shut off and I was sliding out of control. The oil pan had exploded and my wagon was actually on fire from the moment it blew until I came to a stop. The oil covered the rear tires so as soon as I applied the brakes the rear end stepped-out. I got lucky, real lucky as the rear tires came out of the oil slick just in time to slow down enough to allow the front wheels to grab and nearly avoid the curb. Both my front bumper and front passenger side wheel have red paint courtesy of the concrete so I literally just shaved the edge.

There was a modded Evo behind me with 2 occupants who had first-row seats for the show, they stopped to make sure I was ok and of course ask, "what the fvck happened?" We talked for a bit and they helped me collect pieces of my engine from the roadway as I waited for the tow truck.

The wagon is now back in my garage and I am about to dissect in and assess the damage. I will update this thread with my findings.


This should be fun,
Evan

....and boom goes the dynamite!




You can see where my rear tires got traction after the oil


Also you can see the path of my front tire in the gutter


Too close


Bumper kiss, hard to believe there wasn't more damage considering both the bumper and wheel struck the curb


Sorry environment


Carnage I picked up from the road


This is the second time I used this tow truck driver, he assisted me last time when I snapped a rear axle. He pulled up saying, "what did you do THIS time?" lol




Dropping engine chunks everywhere


N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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I6+TT=FTW I6+TT=FTW is offline
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Default 03-18-2016, 02:57 PM

This makes me nauseous man, sorry to see this. Good luck on the rebuild.


2007 Jet Black E90 335xi /PTF-Cobb/E50/FuelitS2/5" Stepped FMIC/Synapse BOV and Charge Pipe/Black 19x8.5/245s all around/and more
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viperware viperware is offline
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Default 03-18-2016, 03:25 PM

Holy crap!


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ByYou335 ByYou335 is offline
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Default 03-18-2016, 03:27 PM

dang man sorry to see that happen. hopefully you get it back up and running stronger than ever! pretty impressive carnage tho
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Default 03-18-2016, 03:30 PM

****!!!

Sorry to hear bro!! And you maintain your car in the highest fashion also! This is scary.

What boost, trims etc were you running?
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Default 03-18-2016, 03:32 PM



Burger Motorsports
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Default 03-18-2016, 03:48 PM

Why does cyl 5 sound like the weak link?!?


2007 E92 335i 6MT
New Jersey
N54-Tuning 3'' Downp!pes, Vrsf 5'' Intercooler, Vrsf Charge Pipe, Tial-Q BOV, Vrsf Lower Charge Pipe, Act HDSD Clutch, JB4 G5 ISO, BMS Intakes, Custom Axle Back w/ 3" Tips
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Default 03-18-2016, 05:11 PM

Thanks for the words of encouragement.

Car is back in my garage and I am getting into it. This is my first blown engine and first time being around one. The damage seems pretty catastrophic, about 3/4 of my oil pan almost blew off and the #3 piston devoured everything around it, there are holes between the turbos on the hot side and under the HPFP on the intake side that I can stick most of my hand in (I am huge).

I will post up some pics later. I would be surprised if the turbos are not toast as well.

Evan


N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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Default 03-18-2016, 05:16 PM



but, new engine = no more 5 cylinder misfire

interesting to know the reason, what happened


2007 E92 335
ST - GTW3684
JB4 G5, ST Pump Flash, Fuel-It Stage 1, Meth
MT (after swap),
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Duperstar Duperstar is offline
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Default 03-18-2016, 05:39 PM

I literally yelled "oh no!" out loud. Good luck man I've been following all of your threads.


2009 535xi - JB4 G5 ISO -BMS Race Flash- BMS Intake - ER CP- Forge DVs- Active Autowerke intercooler- Gone

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Levan-i Levan-i is offline
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Default 03-18-2016, 05:47 PM

wrong tab
----------------------------------------------------------------


2007 E92 335
ST - GTW3684
JB4 G5, ST Pump Flash, Fuel-It Stage 1, Meth
MT (after swap),
MFactory LSD
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Default 03-18-2016, 05:59 PM

Custom flashes or off the shelf? Recently updated or old?
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Default 03-18-2016, 08:14 PM

Im so sorry to hear about this... Glad your alright and Im glad the damage to the rest of the car is minimal. Could have been much worse if you were in a higher gear

Do you have the log?


2008 e61 535xit: VTT GCs, Fuel-it PI, fuelab FPR w/ return line, stage 2 lpfp, fuelab "700" inline pump, RB external PCV, VRSF 7.5" race FMIC, Inlets, outlet, AR ***, 3" chargepiping, 3" exhaust, JB4, BMS PI controller

Last edited by samstryker; 03-18-2016 at 08:21 PM..
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Default 03-18-2016, 08:41 PM

Quote:
Originally Posted by Levan-i


but, new engine = no more 5 cylinder misfire

interesting to know the reason, what happened
True about the cylinder 5 Levan ...assuming I acquire an engine that doesn't misfire on cyl 5! lol! I am not in the clear yet!
Quote:
Originally Posted by Duperstar
I literally yelled "oh no!" out loud. Good luck man I've been following all of your threads.
Thanks for the support! This should be an interesting chapter in my E61 build
Quote:
Originally Posted by dawhiz
Custom flashes or off the shelf? Recently updated or old?
OTS, JB4 with the 32.0 (IIRC) and JB4 Hybrid PI backend (MHD). For the record I 100% blame myself for this incident, absolutely no way I will blame this on the tuning/software I was running, this is my car and I will do what I want with it and take responsibility for my actions.

Evan


N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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matthewo matthewo is offline
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Default 03-18-2016, 09:23 PM

wow that is some carnage. sorry to see it, hope your back and running soon
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Default 03-18-2016, 09:56 PM

Quote:
Originally Posted by matthewo
wow that is some carnage. sorry to see it, hope your back and running soon
Thanks, I appreciate it.


N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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Default 03-18-2016, 09:56 PM

Dropped the brush guard or whatever this thing is, found oil and metal.




No time to be sorry, time to clean and prep components for reinstall (if they are not too damaged).


Intake routing: I meant to do that when most of the components were removed for my VTT turbo-to-IC charge pipe a couple days ago but I forgot, thankfully the blown motor made it happen!


Carnage on the upper driver side. I am VERY lucky the fuel system was not compromised, it would have been bad news if high pressure fuel was spraying everywhere when my car was already on fire!


A look inside


You can see daylight from the other side....


Lower passenger side carnage. I have a uniquely shaped oil pan being a 535xi, but notice the vertical fracture...


Close up


...but wait, there's more!


Another view


From the driver-side, this front 1/2 of the oil pan is loose when I wiggle it, it almost completely blew off!


Notice the cigarette pack sized hole at the top of the photo...


Here is a look inside


Now the real carnage, the lower passenger side just below the turbos. The block and engine mount were almost completely separated.


Notice the bracket at the top and how much further the right side is protruding


A look inside


Another view


More shrapnel


N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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Default 03-18-2016, 10:03 PM

Damn time to slap a motor back in her!


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ms335i ms335i is offline
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Default 03-18-2016, 10:33 PM

Evan just judging from your previous work I am sure you will knock this out quick and it will turn out better than it was before.
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N54GOTU N54GOTU is offline
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Default 03-18-2016, 11:27 PM

Sorry to hear it buddy
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Levan-i Levan-i is offline
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Default 03-19-2016, 12:23 AM

so what was the reason?


2007 E92 335
ST - GTW3684
JB4 G5, ST Pump Flash, Fuel-It Stage 1, Meth
MT (after swap),
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Default 03-19-2016, 01:30 AM

Quote:
Originally Posted by Levan-i
so what was the reason?
I am not familiar enough with engine failure to make conclusions off the information I have at this point. The engine may need to removed at dissected before we know exactly what happened. I will try to share most of the process so even if I don't have answers, we can evaluate the data together.

Evan


N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes, M5 Rear Suspension
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Trans Swap, MFactory SMFW, Spec Stg 3+ Clutch, UUC SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Lines +Ethanol Sensor
- JB4, Hexon RR550s, Custom Inlets, AR ***, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB Ext. PCV, BMS OCC
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Traf Traf is offline
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Default 03-19-2016, 01:46 AM

Maybe that rod broke and sent pieces everywhere ?


f*** v-bands clamp
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Default 03-19-2016, 05:38 AM

Such a perfect car. I'm sure you'll get it back together and better than ever.
For some reason, I am already thinking that there was a cylinder cut and went hyper lean detonation. I guess there may be an assumption that the tbi was going, and the injector wasn't


2007 335i 4dr JB4, Hexon RR600, Inlets, 4Bar, Index 12, Boost Concept Pump, DCI, FMIC, DP and full exhaust, Burger Meth, MHD BEF. Auto.
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Default 03-19-2016, 05:46 AM

Doesn't look like #5 blew. But yeah you did it about as catastrophically as possible lol...

Sorry man, I can relate. Wastegate line blew off on the dyno, let my 6262 go into freespin, next thing we know it probably hit 50psi and now I have low compression on #1 and #6. **** happens! Just have to build it better next time...




2008 AW e92 335i
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