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      01-30-2019, 07:29 AM   #1
mccandless
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135i Turbo rebuild - my winter project

My wastegate rattle has been getting worse over the last year, so i decided to take a chance and get the turbos rebuilt. And i may as well get the internal components upgraded while I've got them out.

I'm on a pretty tight budget. The car is a 2009 with 120km. I only paid $12,000 for the car, so i'm not willing to spend $5000 on turbo upgrades/repairs.

I'm not a mechanic but any means, but i can follow instructions and i have friends who are real mechanics if i get into trouble.

Started the disassembly over the weekend, removed all the engine covers, and bottom tray. I also removed the from bumper because I'm having issues with the headlight motors and they had to come out.
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      01-31-2019, 07:24 AM   #2
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Took off the headlights and some other front bits, removed the front sway bar, and drained the oil. Tomorrow the coolant and removing more bits.
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      01-31-2019, 08:39 AM   #3
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'09 135i  [5.00]
Nice- this is going to be fun to follow!

Who are you getting to rebuild the turbos?
Are you thinking about other preventative maintenance while you're all up in there- water pump for example?
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      01-31-2019, 01:40 PM   #4
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Quote:
Originally Posted by 1and1 View Post
Nice- this is going to be fun to follow!

Who are you getting to rebuild the turbos?
Are you thinking about other preventative maintenance while you're all up in there- water pump for example?
I haven't decided how I'm going to do the turbo rebuild yet, still doing research. The water pump was replaced two years ago, but i'll still have to replace the gasket and bolts since it needs to be removed to get access to the turbos.

I will probably do the oil pan gasket too while i have easy access.
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      01-31-2019, 02:03 PM   #5
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Just had my Indy shop replace/upgrade my wastegates. I haven't had much of a chance to drive it due to the weather here. My mechanic said my turbos looked fine.
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      01-31-2019, 04:20 PM   #6
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I like your helper, OP.
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      02-01-2019, 06:44 AM   #7
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I like your helper, OP.
She doesn't know much about cars, but she's always willing to help.
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      02-01-2019, 09:00 AM   #8
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Is the price differential so great that it isn't worth upgrading? I haven't looked into it at all, but with all the sweat-time you're putting into this, it feels like a shame to come out the other end with stock power.
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      02-01-2019, 10:55 AM   #9
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So i got lucky and found a local person selling a set of new oem turbos (he decided to go hybrid with his 135). I ended up paying $1300 CAD ($1000 US), so i couldn't pass up that deal. Now i don't have to worry about sending them away to be rebuilt. I have the JB4 with an extra 100hp and thats enough for me. This car is going to be for track use so i need dependable power with upgraded handling.

I'd rather spend my money on suspension, brakes and tires.
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      02-01-2019, 04:52 PM   #10
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Quote:
Originally Posted by Soterios View Post
Is the price differential so great that it isn't worth upgrading? I haven't looked into it at all, but with all the sweat-time you're putting into this, it feels like a shame to come out the other end with stock power.
yes, but...

upgraded twins are going to cost $1000 extra minimum, probably $2,000. No matter what you do, that's still a fair whack of cash.

Also (importantly) all aftermarket twins have a reputation of smoking - so if you do upgrade, you have to accept the risk you'll be doing the same job again within 10,000 miles.

New/reconditioned stockies will probably last another 100,000 miles - so it's a safe choice.

.. hence why so many people upgrade to single turbo.
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      02-04-2019, 08:56 AM   #11
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Another problem to add to the list. They seem to be adding up quickly. So when i removed the under tray, i noticed some oil on it. My first thought was "oh #$!%, what now". But after some looking i found that it was the oil filter housing gasket. Not too bad, but another item to add to the list.

Now i'm wondering if i should clean the valves since the intake has to be loosened anyway to get at the oil housing bolts.
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      02-05-2019, 11:20 AM   #12
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Ordered some parts today. The exchange and duty charges are nasty for shipping to Canada, but still way cheaper than dealer prices.
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      02-08-2019, 08:23 PM   #13
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Oil filter housing is off. What a huge mess. Oil and dirt all over the front of the engine. I wish i had seen this leak sooner. Looks like I've got a lot of cleaning to do I took the radiator fan out so i could have more room, i would have done that sooner if i had known how easy it was (one screw and one clip)

Oil has been dripping onto the serpentine belt (probably the reason it's sprayed all over the front of the engine). Does the belt need to be changed now?
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      02-08-2019, 10:58 PM   #14
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hey, you're not to far away from me. NB here.

I went through all that last year with my 135. It wasnt fun, but learnt a lot.
-New valve cover gasket
-Oil pan gasket
-Rear main seal
-front main seal
-Both oil filter housing gaskets
-Walnut blast
-Coolant hoses
-Turbo drains/o rings
-New RB chra turbos with wastegate repair kit
-New injectors

If you have jb4, id invest a little more and get the BEF. You wont be getting 100hp just with jb4 alone on our gas. I sold my jb4, went straight MHD and looking for a custom tune this spring.

While you got that out, check the coolant hose right next to it. Its very brittle and known to break. Id also suggest a new belt if you had that gasket leaking.
You dont want to break it and get sucked into the oil pan.

Once you got all the maintenance done, its a great little car to drive, especially if you get the fbo.
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      02-11-2019, 03:43 AM   #15
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Keep the posts coming man. I will be doing similar maintenance soon.
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      02-13-2019, 05:35 PM   #16
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I got my parts today. ECS Tuning was great to deal with, got everything I ordered.

However UPS sucks here in Canada. The package showed up at my door with over $300 in C.O.D. fees. $119 in taxes (which is fine, i expected to pay that).
Plus $180 in brokerage fees from UPS . It's a total scam and they basically hold your shipment hostage until you pay them.

So i refused the item and did some research on self clearing the package myself. All i had to do was pay the $119 at CBSA (Canada customs office) and take the receipt to UPS. Then they had to release the package without the $180 brokerage fee.

The $180 fee is basically a fee UPS charges to pay the customs tax for you.
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      02-13-2019, 06:47 PM   #17
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'09 135i  [5.00]
heck yeah!
The "Box of New Parts" is the beginning of reassembly!
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      02-21-2019, 05:53 PM   #18
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More new parts. A set of index 12 injectors.
Now i'm defiantly over budget.
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      02-22-2019, 12:22 AM   #19
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nice work
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      02-23-2019, 01:16 AM   #20
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How is it doing this job on Jack stands ? I have rebuilt turboes waiting in my garage for install early spring. Oil pan gasket and some other maintenance too while I'm under there .
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      02-23-2019, 04:05 PM   #21
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Quote:
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How is it doing this job on Jack stands ? I have rebuilt turboes waiting in my garage for install early spring. Oil pan gasket and some other maintenance too while I'm under there .
It's been fine so far, but i'm moving pretty slow. I have the engine support bar on and I'm almost ready to drop the subframe. There were some bolts on the steering rack that would have been hard to reach, but since i had the intake off to clean the valves, i was able to reach the bolts from the top. I think the biggest problem will be maneuvering the subframe off around the steering rack, that would defiantly be easier on a lift.
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      02-23-2019, 05:14 PM   #22
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'09 135i  [5.00]
Nice! Looks like you're getting to the exciting part! AFAIK, once you get the subframe out bob' your uncle, easy access to turbos, oil pan, whatever down there...

Looks like a nice engine support- not the average harbor freight special. Share what, where and how much? Like it?
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