Update:
Following the car servicing, I couldn't resist the temptation to increase its power. Around October 2022, I had a downpipe installed by Colab, and
@Xcede Performance took care of the software tuning. As a result, the car's performance improved significantly, reaching respectable figures (218kw 600nm). This upgrade came just in time for MFest, where I encountered an E90 335i on the way and easily outperformed it (suspecting it was in its stock condition). I also had a race with a tuned Focus ST, and once again, my car came out on top. Surprisingly, the fuel consumption remained unchanged even after the tune, and the addition of the downpipe provided a pleasing sound and enhanced the turbo flutter.
Initially, everything was going smoothly, and I thoroughly enjoyed the increased power of my car. However, problems arose in February. While accelerating off a ramp onto the N14, I heard a breaking sound and suddenly lost all power. The car refused to engage any gears or start. I had to wait for three hours for roadside assistance and BMW on-call service. Eventually, the car was towed to Budler, where it was discovered that the turbo core had broken off. I informed them about the modifications I had made to the car, including the tune and downpipe. Budler replaced the core and performed an oil service, and initially, everything appeared to be fine. They mentioned that the turbo core likely broke off due to normal wear and tear.
After two weeks, a loud whining noise started emanating from the turbo. I took the car back to Budler, and they replaced the core at their own expense, suggesting that it may have been a faulty unit that caused the bent core. Another two weeks passed, and the same issue occurred again in early March. This time, Budler decided to replace the core with a billet one, suspecting that the car was operating at excessively high boost levels. They informed me that if the Billet core experienced the same problem, they would be unable to assist and would need to import a core capable of handling the boost. It's worth noting that Budler provided excellent service and maintained good communication throughout the entire process.
After the turbo core replacement, I noticed a more noticeable lag in acceleration. Quick lane changes now necessitated downshifting, whereas before they did not. To confirm this change, I took the car to Xcede for another dyno test, which indeed showed a decrease in torque at lower rev ranges, as indicated in the image below. Furthermore, I observed an increase in fuel consumption with a similar driving style, resulting in a figure of 11l/100km, compared to the previous 10l/100km.
Now, in June, I'm facing the same turbo whine issue as before, but this time it took approximately two months to reoccur, whereas previously it took about two weeks. I'm unsure about the root cause of the problem and I am seeking a second opinion. Could it be related to the boost? Or is there something else that could be causing trouble with my turbo? I reached out to Fastec, but they require only the turbo itself, while Stallion Turbos mentioned they have no issue with the turbo remaining in the car.
What would you suggest I do in this situation?