Rod bearing (?) noise AFTER installing VAC bearings...??

[DMC380]

Hi guys & girls,

Long time forum lurker, but kinda minimal poster here in Oz...

Had my E90 M3 for about 2 years now. Just rolled over 60,000km (~37,000 miles). Love the car. Slowly doing the odd mod here and there - nothing mechanical (yet... ), just tint/paint correction/couple of black trim bits, etc. so far. Not for any reason other than not having the time..

So, I got the rod bearings done locally by a BMW-only mechanic not far from home. They ordered the VAC kit and installed from underneath. They told me that they have done these several times previously, and I've no reason to doubt them as every time I've been there, there has been at least one other customer M3 there, along with a swag of other cars and the shop is always busy.

After the job was done, they said that there was an unusual noise coming from the motor. They couldn't/didn't determine what it is, and weren't sure that it wasn't there before. However as soon as soon as I picked up the car, I heard it. It is new, and I don't like it.

Mainly heard under very light load (even in neutral) up to ~3000 RPM. Beyond that, the engine noise seems to overtake it a bit, but it is still there. Particularly prominent at around 2,250 RPM.

At the same RPM with no load (i.e. on overrun) it is quiet, so definitely load-related. Haven't been game to rev it past 3000 RPM or put any sort of real load on it yet while it's there.

I have my own theory, but would be keen to hear what any of you think it is.

Apologies for the off-angle videos, but I was mainly trying to capture the sound.

Video 1: primarily from in the driver's footwell area -

Video 2: from the steering wheel to see RPM -

I know it's been mentioned to get video/sound from outside the car for this, but it's so damn obvious inside the car, that I figure it's fine. You can hear it outside also, and happy to film/post that later if anyone would like.

Thanks..

[OzCraig]

Jesus... That sounds like conrod or main knock

[bvrider1]

subscribe, sorry but that sounds like you need to drop the pan and reinspect.

[Bartledoo]

Sounds awful. Sorry man :-(

[tdott]

They messed up.

[e92zero]

sounds horrible. sorry to hear.

[kamber]

Damn, that sounds deeply troubling. I sincerely hope the shop you got the install done at stands by their work and owns up to doing whatever it takes to resolve the source of that noise. Hope it ends up being something not-too-bad; good luck man!

[Helmsman]

PP, ensure that the shop is owning up and making it right.
What did the 60k km rod bearings look like btw?

[DMC380]

Thanks for the replies/thoughts.

The shop that did the work actually asked me to take it to another place for another opinion as they just couldn't work out what it was. They were more than happy to talk to whoever I get to look at it, and assured me that if it was something that they'd done/hadn't done, they would make it right.

I (want to?) believe them - they are nice guys and for all accounts I think are trying to do the right thing.

I'll take it to another place this week for a second opinion and let you guys know what transpires.

This was (is!) my dream car for so many years. I love it, but as I'm sure you guys and girls can all appreciate, this is just so f**king disappointing.

[BPMSport]

I would not drive it like that..

[DMC380]

Originally Posted by Helmsman

PP, ensure that the shop is owning up and making it right.
What did the 60k km rod bearings look like btw?

Forgot to mention that.. they didn't look too bad. Little bit of wear, but nothing compared to some of the pics on here.

[bvrider1]

A shop telling me to take it somewhere else is not a shop I would ever work with. I would not drive this at all and not let it leave the lift unless the noise is resolved. Did they pull the oil pan off after the noise showed up? Tell them to inspect every rod bearing and cap. If it was me I would tell them to rotate the crank by hand while I am underneath the car inspecting. I don't trust this shop.

Keep us posted on what you find out. The shop should be paying for all the damaged goods right?

Originally Posted by DMC380

Thanks for the replies/thoughts.

The shop that did the work actually asked me to take it to another place for another opinion as they just couldn't work out what it was. They were more than happy to talk to whoever I get to look at it, and assured me that if it was something that they'd done/hadn't done, they would make it right.

I (want to?) believe them - they are nice guys and for all accounts I think are trying to do the right thing.

I'll take it to another place this week for a second opinion and let you guys know what transpires.

This was (is!) my dream car for so many years. I love it, but as I'm sure you guys and girls can all appreciate, this is just so f**king disappointing.

[Bus Driver]

Sorry to hear about this OP. Hope the shop will get this sorted out for you soon.

After reading tons of posts on the RB, I'm on the verge of doing it too with a shop who's done a couple of cars here and this is one of the things that's worrying me.

[L4ces]

The shop would have noticed that noise when they started the car up to put it on the lift.

[deansbimmer]

If it is bearing related then the more you drive or run it with that noise the more likely it is that the crankshaft is being damaged. Repair costs will soar maybe to the extent of requiring engine replacement.

At first I thought something could be caught in the accessory belts but you say its prevalent only under load.

Run the engine only if absolutely necessary. The shop doesn't sound qualified (or keen on standing behind their work) if they are putting off diagnosis to another shop. They need to bite the bullet and get back inside the oil pan. They're REALLY gonna be upset if all this driving has caused permanent damage and is going to require a new engine.

[///M Power-Belgium]

Originally Posted by DMC380

Hi guys & girls,

Long time forum lurker, but kinda minimal poster here in Oz...

Had my E90 M3 for about 2 years now. Just rolled over 60,000km (~37,000 miles). Love the car. Slowly doing the odd mod here and there - nothing mechanical (yet... ), just tint/paint correction/couple of black trim bits, etc. so far. Not for any reason other than not having the time..

So, I got the rod bearings done locally by a BMW-only mechanic not far from home. They ordered the VAC kit and installed from underneath. They told me that they have done these several times previously, and I've no reason to doubt them as every time I've been there, there has been at least one other customer M3 there, along with a swag of other cars and the shop is always busy.

After the job was done, they said that there was an unusual noise coming from the motor. They couldn't/didn't determine what it is, and weren't sure that it wasn't there before. However as soon as soon as I picked up the car, I heard it. It is new, and I don't like it.

Mainly heard under very light load (even in neutral) up to ~3000 RPM. Beyond that, the engine noise seems to overtake it a bit, but it is still there. Particularly prominent at around 2,250 RPM.

At the same RPM with no load (i.e. on overrun) it is quiet, so definitely load-related. Haven't been game to rev it past 3000 RPM or put any sort of real load on it yet while it's there.

I have my own theory, but would be keen to hear what any of you think it is.

Apologies for the off-angle videos, but I was mainly trying to capture the sound.

Video 1: primarily from in the driver's footwell area -

Video 2: from the steering wheel to see RPM -

I know it's been mentioned to get video/sound from outside the car for this, but it's so damn obvious inside the car, that I figure it's fine. You can hear it outside also, and happy to film/post that later if anyone would like.

Thanks..

Wow ! Your S65 sounds terrible wrong and I'm 100% sure something went wrong with your bearing replacement !
I can hear rod knock ! So please don't start your car again ! Because every single rpm can cause irreparable damage to your S65 !

But your situation is complicated ..

Shop 1 replaced your bearings .
And shop 1 agreed you take your car to another shop (shop 2) because they are not able to diagnose your abnormal noise .

Advice:

Before you take your car to another shop (shop 2) => *Don't start your car again and please put your car on a trailer for further transport*
Trailer = Avoiding further damage !
Shop 1 should/must write you first something on a paper *And before you take your car to shop 2* *that they will cover/refund* *all* your extra repair costs in shop 2, including engine damage !
I'm pretty sure the repair costs in shop 2 will be higher than the bearing replacement from shop 1 !
Show your videos in shop 2 and ask what they think about the abnormal noise..
Ask advice and show your videos in more shops before you choose shop 2 .
Make sure shop 2 has the necessary S65 knowledge before you take it to their shop otherwise the situation becomes really complicated !

Thank you Dave for your PM (I replied your PM) and please keep me posted about your situation ...
Meanwhile I truly hope that I'm wrong ...

-Philippe.

[pbonsalb]

Not a good sign. Hope it is something external they screwed up that won't hurt anything, like a pulley or belt or tensioner issue.

[Sephiroth]

Maybe its worth dropping the oil pan and check for shavings? What a horrible situation

[Solo_M_Tech]

You need a new shop. They (speculation) installed the rod caps incorrectly and torqued them down. This will not only create rod knock, it has destroyed the connecting rods and they will have to be replaced. Sorry for your loss but that's the most likely situation.

[K-M3]

Originally Posted by Mike Benvo

I would not drive it like that..

This ... that's bad engine internals ... rod ... main .... anything else .... I am by no means an expert but that needs a good n experienced engine man ... maybe even the dealer ....

Oh ... n I don't buy it for a shitty second that the shop that did the job can't figure this out ... they know .... oh they know .... I share your anger man ... any chance you want to lawyer up for this ??

[deansbimmer]

Originally Posted by Uber///M

You need a new shop. They (speculation) installed the rod caps incorrectly and torqued them down. This will not only create rod knock, it has destroyed the connecting rods and they will have to be replaced. Sorry for your loss but that's the most likely situation.

I agree with this as the most likely explanation.

[SYT_Shadow]

Stop driving your car. Do not start it one more time.

It's likely your shop screwed up the install. That or the clowns at VAC shipped the wrong bearings to you. It's happened more than once.