Ok to start off, I have a 2004 MCS w/ 71,000 miles on it. I have intake,headers,cat-back. I haven't had a single problem until I changed out my pulley for a MiniMania 15% reduction pulley + belt. I followed all the steps and when I was done and fired her up. I got a HUGE whining noise from the supercharger, after about a minute my exhaust pipes were glowing red, and at idle it reved from 1100-2000 Rpms erratically. I know the ECU takes time but after 4 hours and some quick drives and additional ECU resets (battery disconnects and ODO reset) I'm lost here. I checked the belt and it's not slipping and the pulley "seems" fine. Any ideas? I'll try anything now!

 

Oh and surprisingly enough car is not overheating but the check engine light is on. -Exhaust is still heating up way more than normal, its at the point I think it's starting to burn the headers gasket up.

 

I have an Alta 15% Pulley and my supercharger whines loud too and I have the same set up as far as exhaust but haven't noticed the pipesgetting hot nor the rpm's jumping except they will be at about 800 at idle and 1000 with the air on. But my engine light and gas filler light will come on at times when I hammer on it from say 1st through 3rd gear. If you find out the problem please post it in case mine copy's off your car.

 

Yeah when I mean it whines loud I mean my wife heard me coming from 2 blocks away while she was inside with the tv on, even at idle it sounds like im going 5500rpms.... kinda like its winding up to blow up 8(

 

Sounds like the pulley is slipping...
Upon inital install, there might have been a sumbles if done right, and that would have been it. When done wrong, major carnage can result....
You did use a tourqe wrench for the install of the pulley right....the tourque on this little nuts is super important....
The way it is running now is likely destroying the sc shaft at the least....
The pulley you pulled of was the oem correct...
There might be a bit f a pulley alighnment issue too....hard to tell without hearing it...
If the pulley is slipping....depending on the dammage, you might be able to install an alta v2 pulley....the mounting system, while not liked by many, is generaly more tollerant to sc shaft dammage from a prior pulley.....
The amazing is it sounds like you just did not park it...you are driving it with this issue...
After pulley install...the only change should be more power...and a slight increase in sc sound if you have a CAI.....

 

+1 on the pulley slipping. If you have driven it as much as you say you have, you may have a problem getting it tight now as Zippy pointed out. Bottom line is that you need to stop driving it and get it pull back apart.

What puller did you use to get the old pulley off?

 

It was an OEM pulley, used a rental tool to take it

 

It was an OEM pulley, used a rental tool to take it off. Wasn't hard and shaft was fine. I used a new digital torque wrench to the 5ft lbs specified on the install sheet. So if it's done enough damage is there a way to replace just the shaft?

 

Nope....a dammaged shaft on a sc may not even allow it to be a core for a rebuild...
Depending on the dammage, the altav2 mount MAY work...
5 ft pounds does not sound right.....

 

Should be approximately 60 inch pounds.

Sorry, not sure how the "foot" got in there.

 

The paperwork says 5ft lbs or 75 in lbs. But on that note I removed the pulley and no scoring of the shaft or signs of slippage on the shaft or the pulley..... So any other ideas? I checked for looseness and play in all the other pulleys I.e tensioner/alternator/A-C but Couldn't check crank pulley. Could the crank pulley be out or maybe a bearing inside the supercharged gone out due to the smaller SC pulley? I know I'm reaching but I'm lost here.

 

OK, my bad on the in pound conversion. I pulled that from another set of instructions that are clearly wrong. 60 inch pounds is 5 foot pounds so you are correct.

Well, if it isn't the pulley that is spinning it is hard to say. Can you get a recording of the noise posted and we can see if we can identify it. It is possible that the SC died in all of this or perhaps it is just the belt slipping. What size belt did you use?

 

I would record but the engine is still out while I figure this out, the new pulley came in a packaged deal... Pulley, belt and removal tool from MiniMania. I hope it's not the SC.

 

Call MiniMania about your problem. I believe pulley's have a lifetime warranty if the problem is with the pulley.

 

Take a look at the harmonic damper...check for slippage/failure where the rubber and the metal meet....
If the sc was fine before the pulley install, it should still be fine....as long as you were gentle removing the factory pulley, and did not beat/wail on it....you said you used a rental tool, so I think you are fine.
Look st the belt you removed.....any signs of missalighnment...shiny edge or white showing?
Maybe it wad not seated 100%, so you were hearing a massivly missalighined belt squeel...
if thrcharmonic damper looks good...no rubber dust or funny smell, just reinstall....use a new belt imo $20, cheap, and try it again.
Good to hear the shaft is ok!! Maybe you just had some bad luck with an alighnment issue.

 

Ok so dampner looks good, and reinstalled pulley and made a video for you guys to give you a better idea, have a new hissing noise so i have a vaccum leak somewhere now but belt still sounds about the same.

http://www.youtube.com/watch?v=OxZjqShhgC0

 

Ok so buy a scanguageII and found two code:

P1109- Manifold air pressure too high in deceleration
P1242- Secondary upstream manifold air pressure too high in deceleration.

I was told by a local BMW repair shop (only BMW shop in town that would talk to me about mini's) that it sounds like a tuning issue, that too much airflow would cause the high pitch whining from making the SC spin too much.

Any thoughts?

 

ECU Tuning is not your problem. You have something else wrong. Vacuum leak, sensor bad, crank pulley coming apart, belt tensioner not working, pulley on wrong, supercharger damaged, and so on it's a really long list of possible things, but tuning is NOT the problem, there are thousands of MINIs on the road with pullies and no tune running fine.

 

I agree with Way here. There is a long list of things that could be causing the problems, but tuning isn't it.

 

Sounds like that shop is pretty useless....bet they have never seen a pulley on a mini....
That sound on the vid is pretty interesting....sounds like a rubbing sound or something...was somebody reving the motor for you? Have you checked all mounts...you did support the motor from below when you did the install right...did you do anything else...like add a tensioner stop? Did you check to see if any of the other pulleys...the idler ones are ok...maybe a bearing went bad...just guessing....but with something like this, you need to track down theclocation of the noise...heck from the signature it sounds like you know your way around a motor....good luck.

 

PS
Are those codes active...light lit....or just stored?
did you check to make sure the computer is plugged in securely...and folks have run 19%, no tuning,no codes....not a good idea long term imo, but just to demonstrate the bmw shop is full of BS.

 

Exhaust glowing red at idle sounds like an air leak or very retarded timing.

 

Sounds like you have a major leak at your intercooler hoses or somewhere post throttle body.

That would explain the LOUD supercharger noise, and the erratic idle.

 

Update: Cleaned out my throttle body and the irratic idle went away mostly, then replaced the bypass valve and now it runs like a champ. Guess with new pulley the valve wasn't closing fully to create the vacuum to open up the TB.... I guess the pulley upgrade just helped me find an existing problem.

 

Glad to hear you fix your problem, How are you liking your S.C pulley now? I am about to install mine this week. This has been a helpful forum, good info from all.