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      11-17-2012, 04:42 PM   #1
CT_335D
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2009 BMW 335d Engine Problems

Hello, I am new to this forum and had a question to see if anyone else is going thru the same problem with their engine as I am.

I purchased a CPO 2009 BMW 335d with 46,700 miles on it about three weeks ago from a BMW dealership about 80 miles from my house. The SERVICE ENGINE SOON light turned on the first week I had the car. Brought it over to my local BMW dealership and they replaced the mass air flow sensor. During the second week I had the car, the SES light turned on again, so I brought it over to the dealership thinking it was probably another sensor. After running tests on the car, they determined that the problem was CARBON BUILD-UP.

They told me that they ordered a new cylinder head, intake valves, and new injectors. When I asked the service rep to tell me what the hell is going on, he said that the injectors failed and leaked, causing sludge and build-up on the intake valves. He said that this was the first DIESEL 335d that he saw this happen to. So they received the new parts this week, but they were not assembled. The service rep to told me that they need to have the machine shop do some work on it and it will take one more week to complete everything.

So now it looks like they are rebuilding my engine. I am not a mechanical person, but doesn't seem a bit extreme with a car that only has about 47,000 miles on it. Just wanted to find out if anyone else had similar problems with their diesel engines.

After all is said and done, I will have a rebuilt engine. The service rep told me that the total cost of the work being done on my car is about $10,000. It's good that the car is CPO and comes with the extended warranty, but what if this happens again after the warranty runs out. There is no way I want to pay that much money to fix it.

Last edited by CT_335D; 11-17-2012 at 05:22 PM. Reason: first post did not send so I did a test to see if i can post anything
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      11-17-2012, 05:19 PM   #2
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...nevermind, original post read "test", hence my confusion.

I can't believe there's anther one. I'm getting a bad feeling about all this nonsense of late.
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Last edited by FormerRotor; 11-19-2012 at 06:21 PM. Reason: Change of original post
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      11-17-2012, 05:33 PM   #3
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OP, there are others:

http://www.e90post.com/forums/showthread.php?t=770163

http://www.e90post.com/forums/showthread.php?t=739699
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      11-17-2012, 05:36 PM   #4
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you have to drive it hard most of the time to avoid carbon build up!
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      11-17-2012, 05:43 PM   #5
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After talking to the BMW service rep, he said that there was some carbon build-up, which they will take care off, but the main problem was the leaking injector.

They will be replacing all six injectors, intake valves and cylinder head. I just hope these new injectors will not fail like the current injectors did only after 47,000 miles.
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      11-17-2012, 05:53 PM   #6
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Quote:
Originally Posted by CT_335D View Post
After talking to the BMW service rep, he said that there was some carbon build-up, which they will take care off, but the main problem was the leaking injector.

They will be replacing all six injectors, intake valves and cylinder head. I just hope these new injectors will not fail like the current injectors did only after 47,000 miles.
Jesus another one...

Ask your SA if the injectors are the same part or if BMW is installing a new type of injector.
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      11-17-2012, 06:27 PM   #7
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I will ask the SA on Monday. I asked him if the new injectors will have the same problem after 47,000 miles and he said that new ones are better. That I should have no more problems. The SA said that the rubber portion or seal is what failed. Does anyone have a picture of the injector that shows the rubber seal?
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      11-17-2012, 06:36 PM   #8
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Quote:
Originally Posted by CT_335D View Post
I will ask the SA on Monday. I asked him if the new injectors will have the same problem after 47,000 miles and he said that new ones are better. That I should have no more problems. The SA said that the rubber portion or seal is what failed. Does anyone have a picture of the injector that shows the rubber seal?
Hmmm, if the new ones are better that would imply something is different with the new injectors - perhaps the rubber seal, perhaps an entirely new injector.

I will be curious to hear what your SA says - see if you can get the part number for your old ones and the part number for the new injectors.

Good luck
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      11-17-2012, 08:09 PM   #9
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I just don't understand why they need to replace the cylinder head to replace bad injectors. The intake valves are probably dirty and need to be replaced. The injectors are leaking and need to be replaced, but why the cylinder head?

Also, wouldn't the fault codes tell the tech what is wrong with the car. Why tell me that it's carbon build-up first and then they tell me it's the injectors? When my car is finally fixed and ready for pickup, I will ask the tech if this happens again after my CPO 100,000 mile warranty, will BMW cover this problem if it comes back?

Also, when they need to replace parts, do they order them from Germany? The reason I ask is because it takes them 5-6 days to get them once they order them.
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      11-18-2012, 04:55 AM   #10
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I'm also curious as to why the need to replace the cylinder head...

Fault codes only aid in troubleshooting. Often times a fault code is not even directly related to a part that fails. I'm sure they assumed one thing but once the tech dug deeper removing parts the real cause was found.

Please keep us d owners updated as to the outcome and what will be covered in the future.

I wouldn't doubt that parts may have to come directly from Germany, or at the very least from across the country from another dealer that may have those items in stock. The 335d is fairly rare here in the states probably <10,000 units sold here since they were introduced as '09 models.
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      11-18-2012, 07:53 AM   #11
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http://www.enginebuildermag.com/Arti...be_tricky.aspx

This is a good writeup on diagnosing injector issues in a common rail diesel and why it can be difficult.
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      11-20-2012, 09:06 AM   #12
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Originally Posted by 335dM View Post
you have to drive it hard most of the time to avoid carbon build up!
Wait, is this true?
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      11-20-2012, 09:37 AM   #13
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Quote:
Originally Posted by Jhayd11
Quote:
Originally Posted by 335dM View Post
you have to drive it hard most of the time to avoid carbon build up!
Wait, is this true?
Yup!
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      11-20-2012, 12:42 PM   #14
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Yup!
I agree 100%. 335d was built to provide great MPGs at barely legal hwy speeds. If one is looking for a fuel sipper buy a VW Tdi. That's my story and I'm sticking with it.

Actually this goes for all BMW's more or less.
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      11-20-2012, 05:47 PM   #15
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I think I'm going to add a 2/10 micron secondary fuel filter and as well add water injection
I use to be an aircraft mechanic and water injection would be very very helpful on our engine )))
This combined with driving hard the car and perform diligence maintenance and no more carbon build up in our cars as well as longer injector durability !
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      11-21-2012, 05:49 AM   #16
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I drive my DIESEL like a PIMPED out prostitute and although Im at 22K I hope I dont run into these issues, even though BMW states not to use a Cetane Booster and DIESEL injector cleaner I do use it, unless SOMEONE here can clarify to use this issue, Chris u know anything on this?
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      11-21-2012, 11:15 AM   #17
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I'm about to buy a 2011 335d - all these head rebuilds/engine failures due to carbon buildup is having me worried. Is there a DIY written on cleaning up your intake system and how to prevent additional buildup (oil catch can etc..)? Should I even be worried?
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      11-21-2012, 04:18 PM   #18
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Quote:
Originally Posted by 35mphgolf
I'm about to buy a 2011 335d - all these head rebuilds/engine failures due to carbon buildup is having me worried. Is there a DIY written on cleaning up your intake system and how to prevent additional buildup (oil catch can etc..)? Should I even be worried?
I think I'm going to add a 2/10 micron secondary fuel filter and as well add water injection
I use to be an aircraft mechanic and water injection would be very very helpful on our engine )))
This combined with driving hard the car and perform diligence maintenance and no more carbon build up in our cars as well as longer injector durability !
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      11-21-2012, 04:37 PM   #19
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Quote:
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how to prevent additional buildup (oil catch can etc..)?
I *think* the carbon buildup is tied more to the use of the EGR system than oil. My limited understanding is that modern diesel engines are running much more aggressive EGR (higher volume), and that is the underlying cause. OTOH, I might be wrong.

I for one will investigate options for closing off the EGR valve and coding it out once I am out of warranty.
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      11-21-2012, 05:16 PM   #20
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The EGR part makes sense...
Unfortunately I'm at a loss for the water injection. How would that help and where would it go?
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      11-21-2012, 08:46 PM   #21
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Is the current 335d EGR system like the older european e46d systems? The valve in the EGR only opens at low speed (vacuum pressure) and closed as RPMs and pressure increase...? Which explains why it really is better to rev and drive spiritedly.

If that's the case and its vacuum operated, can we just plug it up to keep the valve closed?

DieselDiner: I'd be thoroughly interested in a coding option or EGR delete! What tool are you using for your coding? I'll be picking up my 335d in 2-3 weeks and would like to be able to code too.

Thanks!
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      11-22-2012, 02:59 PM   #22
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Unfortunately I'm at a loss for the water injection. How would that help and where would it go?
IIRC, the water injection lowers combustion temps, and reduces nox and particulates too. The system would be aftermarket - member TDIwyse has installed a system, I'll try to find a link.
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