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Root cause for SES light (Injector(s), DDE, carbon build up)
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05-08-2013, 10:07 PM | #1 |
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Root cause for SES light (Injector(s), DDE, carbon build up)
Got the car back after 2+ months today.
Chain of events: Each ">" represents a separate dealership visit SES LIGHT, REPLACE INJECTOR > SES LIGHT, REPLACE INJECTOR, REPROGRAM DDE > SES LIGHT REPLACE DDE > SES LIGHT, REPROGRAM DDE, REPLACE INJECTOR, REPLACE HPFP > SES LIGHT,REPLACE ENGINE HARNESS > SES LIGHT, CLEAN CYLINDER HEAD OF CARBON BUILD UP, SES LIGHT, REPLACE 6 INJECTORS, SES LIGHT, REPLACE DDE, issue resolved To make a long story short, it was the DDE causing the SES light for "Zero Volume Adaptation". What caused the DDE to fail? According to BMW Engineering, faulty Engine Harness was to blame for the DDE electronic failure. If you see the pattern of the visits, DDE was replaced once before the Engine Harness replacement, however, that new DDE was also damaged by a short circuit due to the engine harness after 1000 miles or so, causing it to fail. Now that everything is in place, lets see how it goes. 300+ miles and no issues. The car is driving like it should. So if it is the ENGINE HARNESS causing the DDE failures, shouldn't there be a Technical Service Bulletin from BMW? Is the harness also causing other part(s) to fail? As you can see, the dealer had to keep throwing parts at the car as per BMW Engineering to finally get to the bottom of this. Regarding the build up in the intake, intake valves, and cylinder head: This is a result of the electronic EGR functionality. Is there a way around it? Only way would be to "tune it out". The stock setting for the AIR to EGR ratio needs to be modified. BMW did redesign and reprogram the EGR operation, however there isn't any data yet available if this solved the excessive soot/tar build up. It's been a long journey for me (5 months) to get this 335D back in my hands fixed. Hopefully this never happens again to me, and if it is happening to you, hopefully I have shed some light on this issue. I have had BMW loaner cars for this entire experience. Last edited by 135i_vs_; 05-09-2013 at 05:14 PM.. |
05-09-2013, 04:00 PM | #3 |
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Thank you so much for your report. It will be helpful for all of us! Good luck and we hope that you don't have any future mishaps.
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05-09-2013, 06:15 PM | #5 |
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I do not know what would have been the cost out of warranty but I imagine it is very high.
Out of warranty, will we have to replace parts over parts until it solve the problem? Here in Atlanta, I do not need an annual inspection to make sure my check engine light is not ON. Maybe I can live with the check engine light ON, put black tape over it and ignore it. On my car the DDE was not replaced but erased and reflash to fix the problem. Over the course of its life, my 2010 335d DDE has been reflashed few times. I do not think there is any thing wrong with the engine but I think the software bugs are not totally ironed out of this North American version (i.e. pollution control). As I mentioned in a previous post, I had a limp mode with my car after the new software was loaded but no check engine light. I also experienced recently the same rough idle as before but no SES light. I went check for codes and I found the same code as before except that now they are pending codes (fault need to repeat x times to trigger SES light). |
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06-19-2013, 06:17 AM | #6 |
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So far over a month and 2k+ miles, The car is running perfect.
I'm enjoying the power, mpg, and the diesel grunt every morning to work, mixed city/highway with over 30.X mpg+ On the highway set at cruise control 75mph, the car does over 39.2 mpg. No regrets with the 335d. |
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06-19-2013, 06:50 AM | #7 | |
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06-19-2013, 08:38 AM | #8 |
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its mind boggoling to see that the SA was told!! to do some other checks and FAILED when in FACT the knew there was a major problem!1 WTF BMWoA just go to the point and fix the god damn thing!!!
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06-19-2013, 09:45 AM | #9 |
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Drilled out broken studs on DPF filter? Well, that is one repair I am not looking forward to.
Thanks for posting all those receipt copies, I didnt see an Engine Harness when I looked through them. Do you have a P/N for the engine harness?
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06-19-2013, 10:22 AM | #10 | |
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06-19-2013, 10:38 AM | #11 | ||
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Apparently gassers which have similar issues theoretically can have less carbon buildup if the electronic controls of the fuel and valves are specifically controlled not to expose the valves and bits to the soot and fuel in direct injected engines: Quote:
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06-19-2013, 10:36 PM | #12 | |
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Somewhere on this forum. I'm not worried about carbon build up issues occuring again. BMW should have gotten it right the 2nd time around with the EGR Recall. |
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