[Yozh]

I thought I would do a thread on the some aspects of the turbo control and vacuum system. Was digging in there the other day and decided to take some pics. May be will be useful to some.

[Yozh]

Continuation...

What I would suggest for anyone having or suspecting to have any issues with their system and anyone who is wiling to open the rats nest of vacuum lines.

[Yozh]

Ok, I guess this is why I started this thread. Just wanted to post some pics.

[Yozh]

For anyone replying. Please do not Quote the whole post. They are rather big.

[TDIwyse]

Outstanding. Thanks for going to the effort to put this together and share with the community.

[DWR]

Excellent job. I'm always impressed by your contributions.

[TorqueAddict]

Thanks for compiling this Yozh!

[335duff]

Thank you so much for the write up!

[iaknown]

Nice job Yozh!

[335dsleeper]

Awesome job, thanks!

[Nadir Point]

+eleventymilion!

[JOHNNYBRAVO1]

Yozh again, you are amazing help and great guy.

[rotatool]

Great job and Thank You for posting such detailed information

[nicklockard]

Hi Yozh,

First, a big THANK YOU for this thread. There's so much good info on this forum but so spread out you can't find it, so it's really nice to have all of this consolidated like you did.

I'm going to replace all vacuum hoses this weekend, test turbo changeover valve, and the other vacuum solenoids, as well as check the red boost hose.

Following your first post here, I checked my vacuum at the EGR cooler to be 200 mmHG at idle and I heard some pretty loud hissing from 1400-3000 rpm's the other night. Car keeps going into limp mode on moderate TPS at EXACTLY 2500 rpm's Is this where LP-EGR kicks in?

I get P2457 and P0299

I have read here and there some people pre-order seals when doing these. I intend to keep the car bone stock (all emissions systems intact) except for adding a chiptune later.

Which seals should be preventatively replaced when doing vacuum lines?

[WreckerX5d]

Originally Posted by nicklockard

Hi Yozh,

First, a big THANK YOU for this thread. There's so much good info on this forum but so spread out you can't find it, so it's really nice to have all of this consolidated like you did.

I'm going to replace all vacuum hoses this weekend, test turbo changeover valve, and the other vacuum solenoids, as well as check the red boost hose.

Following your first post here, I checked my vacuum at the EGR cooler to be 200 mmHG at idle and I heard some pretty loud hissing from 1400-3000 rpm's the other night. Car keeps going into limp mode on moderate TPS at EXACTLY 2500 rpm's Is this where LP-EGR kicks in?

I get P2457 and P0299

I have read here and there some people pre-order seals when doing these. I intend to keep the car bone stock (all emissions systems intact) except for adding a chiptune later.

Which seals should be preventatively replaced when doing vacuum lines?

I would change the seals located in this link , specifically numbers 2 (11618506786), 3 (11617791470), 13 (11617790547) , and 14 (1617791469).

[nicklockard]

Originally Posted by Wrecker335d

I would change the seals located in this link , specifically numbers 2 (11618506786), 3 (11617791470), 13 (11617790547) , and 14 (1617791469).

Thanks!

[Yozh]

Originally Posted by nicklockard

I get P2457 and P0299

Here are the codes you are getting:



This is the BMW equivalent to your P2457:









A few more action in service for the same fault:

[nicklockard]

Yozh,

Yeah, a Torque scan shows an implausible EGR thermocouple showing 0.5 degC when engine running.

I replaced all the vacuum hoses I could reach today. I was a little intimidated to take so much stuff off as you did. However I managed to replace 80% of them, and the 2.5 remaining hoses (I made one splice) are still flexible/pliable. What was interesting was I did find two vacuum hoses badly rotted and leaking.

First I did a poor man's smoke test using a cheap cigar blowing into the vacuum system. I heard and smelled smoke coming from the driver's side of the engine bay, down low, but couldn't see any smoke.

Then I went about replacing each line one by one, often by feel. I was really careful to not snap any plastic nipples and took my time cutting the old stuff off. Also, I was careful not to exceed my mechanical abilities and leave alone the ones I couldn't reach effectively. I also inspected the red boost hose: looks like the top seal is leaking moderately or maybe intermittently at higher boosts. Some oil from the driver's side of the top seal, but not a ton.

Put it all back together and went for a test drive. The limp mode is gone! It pulls REALLY hard from 90-125, like a beast. I tried to trigger limp mode by accelerating in 6h from 1500 rpm's (not crazy) then going full throttle by 2200 rpm's. I did not fault. Still feels a bit sluggish down lower to me though.

EGR fault came back (I'll get the sensor replaced and see if that clears it up).

Tomorrow I'll check functions of valves (PCV's and changeover valve) per your instructions. It just took me too long to do the vacuum lines (I'm slow).

Your thread gave me the confidence to do this--A big thank you, Yozh.

[Yozh]

Here is the info for the P0299 / 4530 code:

Attachment 1506316

Attachment 1506317

Attachment 1506318

[Yozh]

Originally Posted by nicklockard

I'm going to replace all vacuum hoses this weekend, test turbo changeover valve, and the other vacuum solenoids, as well as check the red boost hose.

Following your first post here, I checked my vacuum at the EGR cooler to be 200 mmHG at idle and I heard some pretty loud hissing from 1400-3000 rpm's the other night. Car keeps going into limp mode on moderate TPS at EXACTLY 2500 rpm's Is this where LP-EGR kicks in?

I get P2457 and P0299

I have read here and there some people pre-order seals when doing these. I intend to keep the car bone stock (all emissions systems intact) except for adding a chiptune later.

Which seals should be preventatively replaced when doing vacuum lines?

Do you have an X5 or a 335d, as you had mentioned the LP-EGR?

200 mmHG vacuum is about 8 inHg and you should be pulling about 25-29 inHG (635-740 mmHg). Now, 29 inHg is a system vacuum. For the 335d and HP-EGR cooler bypass, it's either on or off, so either zero or full vacuum. For the X5 LP-EGR, there is no cooler bypass, but there is a pressure converter for the LP-EGR valve itself and I'm not sure where you were measuring the vacuum, please clarify.

From the problem you had written, it sounds like a vacuum problem. But please remember, you need to test the system as a whole. If you have a failed pressure converter for the wastegate, it will affect everything else.

On the issue of hissing. Personally, I have never heard a hissing sound made by our vacuum system, unless you stick a hose to your ear. It does not mean that I'm right though, as a failed pressure converter or a switchover valve could "squack". But for the hissing at 1400-3000 rpm it's most likely your boost leaking. Those seal changes suggested earlier would be a positive change, unless you need a new or aftermarket red boost hose. Hissing could also be exhaust, but you would be smelling it then.

Good Luck.

[Yozh]

Originally Posted by nicklockard

Yozh,

Yeah, a Torque scan shows an implausible EGR thermocouple showing 0.5 degC when engine running.

EGR fault came back (I'll get the sensor replaced and see if that clears it up).

What code did Torque give you? Same as before?

If so, I would not rush to change the EGR (HP-EGR Cooler) temp sensor. That is how they check plausibility for the fault in the HP-EGR cooler bypass. Test that first. Make sure mechanically the bypass switches, then test the vacuum actuator (it's plastic, ugh) holds vacuum, then make sure all vacuum lines to it are good (they are kinda hard to reach), then test resistance on the EUV that controls the switchover, then make sure EUV holds vacuum and does not leak, then test system vacuum at the input to EUV is at 29 inHg when at idle. This should eliminate the EGR cooler bypass (system) as a culprit.

[nicklockard]

Originally Posted by Yozh

Do you have an X5 or a 335d, as you had mentioned the LP-EGR?

200 mmHG vacuum is about 8 inHg and you should be pulling about 25-29 inHG (635-740 mmHg). Now, 29 inHg is a system vacuum. For the 335d and HP-EGR cooler bypass, it's either on or off, so either zero or full vacuum. For the X5 LP-EGR, there is no cooler bypass, but there is a pressure converter for the LP-EGR valve itself and I'm not sure where you were measuring the vacuum, please clarify.

From the problem you had written, it sounds like a vacuum problem. But please remember, you need to test the system as a whole. If you have a failed pressure converter for the wastegate, it will affect everything else.

On the issue of hissing. Personally, I have never heard a hissing sound made by our vacuum system, unless you stick a hose to your ear. It does not mean that I'm right though, as a failed pressure converter or a switchover valve could "squack". But for the hissing at 1400-3000 rpm it's most likely your boost leaking. Those seal changes suggested earlier would be a positive change, unless you need a new or aftermarket red boost hose. Hissing could also be exhaust, but you would be smelling it then.

Good Luck.

It's a 2009 LCI E90 335D. Thanks for the helpful suggestions. I'll do more testing tomorrow.

Edit: (I was mistaken about LP-EGR. I'd thought mine had it.) Torque Pro app has these showing today:

FAULT CODES POSTED BY TORQUE PRO are:

P0299 High pressure turbocharger underboost
P0403 EGR
P2457 EGR

Mode $06 report generated by Torque for Android
================================================
Vehicle VIN: Not present
Vehicle Manufacturer: Unknown
Vehicle Calibration ID: Not present
Test report:
------------------
MID:$01 TID:$e1
- O2 Bank 1 Sensor 1
Max: 3S Min: 0S
Test result value: 0.1S
PASS
----
MID:$01 TID:$e2
- O2 Bank 1 Sensor 1
Max: 3S Min: 0S
Test result value: 0.3S
PASS
----
MID:$01 TID:$e3
- O2 Bank 1 Sensor 1
Max: 5S Min: 0S
Test result value: 0.5S
PASS
----
MID:$01 TID:$e4
- O2 Bank 1 Sensor 1
Max: 23.89869% Min: 17.89845%
Test result value: 20.44993%
PASS
----
MID:$01 TID:$e5
- O2 Bank 1 Sensor 1
Max: 14.06362% Min: 3.06421%
Test result value: 9.73741%
PASS
----
MID:$02 TID:$b1
- O2 Bank 1 Sensor 2
Max: 6.5S Min: 0S
Test result value: 0.2S
PASS
----
MID:$02 TID:$b2
- O2 Bank 1 Sensor 2
Max: 9S Min: 0S
Test result value: 2.5S
PASS
----
MID:$02 TID:$b3
- O2 Bank 1 Sensor 2
Max: 30 Min: -32,768
Test result value: 8
PASS
----
MID:$02 TID:$b4
- O2 Bank 1 Sensor 2
Max: 32,767 Min: -30
Test result value: 8
PASS
----
MID:$02 TID:$b5
- O2 Bank 1 Sensor 2
Max: 1.99958 Min: -9.99424
Test result value: -0.39741
PASS
----
MID:$02 TID:$b6
- O2 Bank 1 Sensor 2
Max: 9.99393 Min: -0.74969
Test result value: -0.39741
PASS
----
MID:$03 TID:$c1
- O2 Bank 1 Sensor 3
Max: 22.49934% Min: 15.49958%
Test result value: 20.33548%
PASS
----
MID:$03 TID:$c2
- O2 Bank 1 Sensor 3
Max: 30 Min: -32,768
Test result value: 0
PASS
----
MID:$03 TID:$c3
- O2 Bank 1 Sensor 3
Max: 32,767 Min: -30
Test result value: 0
PASS
----
MID:$03 TID:$c4
- O2 Bank 1 Sensor 3
Max: 32,767 Min: 3
Test result value: 683
PASS
----
MID:$21 TID:$f2
- Catalyst Monitor Bank 1
Max: 1.99882 Min: 0.34996
Test result value: 0.99991
PASS
----
MID:$31 TID:$81
- EGR Monitor Bank 1
Max: 10 Min: 0
Test result value: 0.07
PASS
----
MID:$31 TID:$82
- EGR Monitor Bank 1
Max: 10 Min: 0
Test result value: 0.32
PASS
----
MID:$31 TID:$83
- EGR Monitor Bank 1
Max: 3,276.69995°C Min: 5°C
Test result value: 0.5°C
FAIL
----
End of report.