"winning is endurance"
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
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
Figure 14b displays the
Valvetronic sensor removed from
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
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
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
Figure 19, Porsche 997 Turbo Wing Hydraulics.
Figure 20 shows three different oil drain
bolts that we commonly find damaged from
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
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
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
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
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
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
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
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).