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BMW 3-Series (E90 E92) Forum > E90 / E92 / E93 3-series Powertrain and Drivetrain Discussions > N57 / M57 Turbo Diesel Discussions - 335d > 2009 BMW 335d Engine Problems - Finally Got my Car Back



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      11-23-2012, 12:37 PM   #1
CT_335D
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2009 BMW 335d Engine Problems - Finally Got my Car Back

Picked up my 335d today. Here is the final report on what they fixed.

47407 Restricted intake air ports in cylinder head. Charge battery and scan for faults: DDE 3FF1 air mass flow sensor. Performed test plan, measured voltage air air mass meter and found to be in specs. Removed lower engine plastic shields and visually inspect air lines: no problems seen. Since vehicle back multiple times, shop foreman to inspect. Scanned vehicle again and performed test plan. Performed test plan for air intake charge and temp sensor which passed. Smoke tested air intake system extensively and found no intake leaks. Per test plan checked air intake system for restrictions BU removing the air intercooler. Found about 0.5 oz oil in air intercooler. Removed intake manifold and inspected ports for blockage with borescope. Submitted PUMA case ########. Per PUMA request, take several sets of pictures and attach to case. PUMA authorization for cylinder head replacement due to intake port restriction in head. See line D for head replacement. After repairs, vehicle test driven 3 drive cycles for approx. 80 miles. No warning lights, charge battery and rescan: All good.

Line D:

Replacing cylinder head removal per PUMA case.

1 Cylinder Head
1 Set Bolt Cylinder
1 Cylinder Head Gasket
1 Gasket Set Cylinder Head
2 Bearing Bolt
6 RMFD Injector
1 Clamp
1 Gasket
1 Gasket
10 Gasket Ring
2 Clamp Hose Clamp
1 Coolant

Faulty cylinder head start removal of cylinder head per PUMA case. DW time for looking for shop tools. Removed intake, fan, belts, EGR, fuel injectors, fuel line and rail, vale cover, low pressure turbo, complete exhaust, SCR CAT converter, high pressure turbo and exhaust manifold. Removed cylinder head and inspected.. Updated PUMAs case with findings. New head came with no valves. Getting sent to machine shop for valve and seals installed. Installed new head, bolts and gaskets kits cleaned. Performed road test.

Line F:

Tech noted trouble shot low fuel pressure. Cause: ning lamp

Removing and installing or replacing pressure sensor at pressure accumulator of injection system.

HDP volume control valve replaced faulty HDP volume control valve cleared faults, reformed road test.

--------------------------------

According to the report and to what the service guy told me, they replaced the cylinder head, injectors, all 24 valves and seals. He also said that they replaced a fuel pressure sensor.
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      11-23-2012, 01:54 PM   #2
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I WILL be getting ext warranty!
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      11-23-2012, 02:19 PM   #3
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I'm still not clear why the cyl head was replaced. Did they give you any additional explanation for this?
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      11-23-2012, 03:00 PM   #4
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Just what I wrote in the initial post. It's must be easier for them just to replace the cylinder head. Maybe someone out there might know the answer to this question. I am just happy to get my car back after 2.5 weeks and I hope this doesn't happen again.
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      11-23-2012, 03:01 PM   #5
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This was what was written on the report.

"PUMA authorization for cylinder head replacement due to intake port restriction in head"
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      11-23-2012, 04:41 PM   #6
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They don't want the tech to clean it and risking damaging the port using high speed dremmel or using abrasive product or thinner or anything similar to the head! So they asked to just replace it then send it to the an engine power plant where they have the right knowledge to clean it properly!
There is your answer
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      11-23-2012, 07:17 PM   #7
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Quote:
Originally Posted by 335dM
They don't want the tech to clean it and risking damaging the port using high speed dremmel or using abrasive product or thinner or anything similar to the head! So they asked to just replace it then send it to the an engine power plant where they have the right knowledge to clean it properly!
There is your answer
That makes sense- the refurbished part can then be used later. Thanks for the insight.
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      11-23-2012, 07:50 PM   #8
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It may be that the low fuel pressure caused all the carbon issues in the first place. -Michael
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      11-23-2012, 08:53 PM   #9
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That's what I think. Maybe my SES light turned on because of the low fuel pressure sensor. So as they started to diagnose the problem, they found the leaking fuel injectors, which lead to the new cylinder head, injectors and valves.

But wouldn't the fault code come back as a bad fuel pressure sensor and just replace the sensor? All of this work that was performed in the last 2.5 weeks to my car just because of a bad pressure sensor.

Don't know how to take all of this in. The tech told me that the total cost to fix my problem was over $11,000. That's quite allot if it was only the fuel pressure sensor.

I just hope I don't have anymore issues with this car, otherwise I will consider selling it and taking a loss.
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      11-28-2012, 12:34 PM   #10
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I have been driving the 2009 BMW 335d since I picked it up last Friday, so about 6 days, and still no SES light, wow!

I did notice that the trip computer is showing better MPG driving the same way as always. Maybe replacing the valves, fuel injectors and cylinder head made a difference.
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      11-28-2012, 08:33 PM   #11
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Good news!
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      12-03-2012, 09:30 PM   #12
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I had this same problem and they also replaced my cylinder head. They told me it was around 14k of parts and labor that was covered. I ended up getting an extended warranty so that I am covered up to 100k as well.
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      12-03-2012, 09:55 PM   #13
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Maybe it's all just a scam to get forum members to buy extended warranties

It sure worked for me!
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      12-04-2012, 07:07 AM   #14
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You never know, it might just be a scam. After the BMW service rep told me that the repairs were over $11k, he started smiling. Then he said something like "this will be a nice christmas bonus". It made me feel that he was excited about the work being done on my car and that it cost so much to fix it. Don't know if it ment anything, but it's the dealership that just made $11k minus the cost of the parts and labor. So I wonder if the service reps get a piece of that earnings in a form of a bonus.
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      12-04-2012, 08:17 AM   #15
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I wouldn't doubt it man. Lots of people felt my air intake manifold didn't have to be replaced and could have easily just been cleaned out. The dealer insisted.

I wasn't going to argue...lol
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      12-04-2012, 07:55 PM   #16
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There are multiple indications that dealers take a good chunk of the costs covered under warranty.
I went for a state inspection with a car clocking 5000 miles.
Virtually new. Absolutely show room condition.
Checking the service invoice, they have changed the windsheild wipers for no reason. $ 80 dollars for the part , $20 dollars labor
As I paid nothing I did not argue. But something is absolutely wrong on this.
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      12-05-2012, 11:18 AM   #17
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So what happens when the car is out of warranty and the service rep at the dealership tells you that you need to replace ccertain parts that will cost lots of $$$?

I think that once my car is out of warranty, I will find a local service station that will do it for a lower price. Someone that works on BMW's and knows what they are doing.

Does anyone know of any good BMW mechanics in the Connecticut area?
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      12-05-2012, 11:21 AM   #18
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There's a ton here in SUNNY Puerto Rico, LOL
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      12-08-2012, 10:27 PM   #19
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Had my SW update service scheduled for last week.
Showed up as planned and surprisingly heard that the latest SW for the 2011d's build after july 2011 is on hold.
Dealer informed that another car had the update done the day before and did not start anymore. They had to re-flash it using the old SW.
My appointment is delayed until a reliable solution is available which I am told may take another month.
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      12-08-2012, 10:48 PM   #20
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Quote:
Originally Posted by Jffeijao
Had my SW update service scheduled for last week.
Showed up as planned and surprisingly heard that the latest SW for the 2011d's build after july 2011 is on hold.
Dealer informed that another car had the update done the day before and did not start anymore. They had to re-flash it using the old SW.
My appoitment is delayed until a reliable solution is available which I am told may take another month.
The same thing happened to me.
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      12-09-2012, 08:19 AM   #21
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Quote:
Originally Posted by GreekboyD View Post
I wouldn't doubt it man. Lots of people felt my air intake manifold didn't have to be replaced and could have easily just been cleaned out. The dealer insisted.

I wasn't going to argue...lol
I have a buddy that's a BMW master tech and him and I discussed this exact thing the other day. I was worried about my car and the carbon build up and asked him whether I could clean my intake manifold as preventative maintenance. I guess they attempted this repair at one point but he indicated that the manifold is complicated enough with the runners and passages that they struggled trying to figure out a way to get it completely clean. They ended up getting it cleaned in a large ultrasonic cleaning tank and said that worked. That said, BMW must not endorse this method as they have been covering replacements of them since.
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      12-09-2012, 10:50 AM   #22
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Quote:
Originally Posted by Jffeijao View Post
Had my SW update service scheduled for last week.
Showed up as planned and surprisingly heard that the latest SW for the 2011d's build after july 2011 is on hold.
Dealer informed that another car had the update done the day before and did not start anymore. They had to re-flash it using the old SW.
My appoitment is delayed until a reliable solution is available which I am told may take another month.
Did the OP mean after July 2010? After July 2011 build would only be a few months of production. I have a after July 2010 and did recieve the SW update about a month ago apparently before they pulled it. No problems at all and it appears as my MPG has returned to the levels I had before the previous update.
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